A METHOD FOR APPLYING A LAYERED TEXTILE TO A METAL SUBSTRATE

Abstract

The present invention relates to a method for applying textile to a plane metal substrate, the method comprising the steps of: providing a coiled plane metal substrate; unwinding the coiled plane metal substrate; applying a further adhesive layer onto a top surface of the plane metal substrate; and laminating a layered laminate comprising a carrier film, an intermediate adhesive layer, and a textile top layer onto the top surface of the plane metal substrate, the carrier film contacting the further adhesive, thereby forming a laminated assembly. The invention further relates to a laminated assembly obtainable by the method.

Claims

1. Method for applying textile to a plane metal substrate, the method comprising the steps of: providing a coiled plane metal substrate; unwinding the coiled plane metal substrate; applying a further adhesive layer onto a top surface of the plane metal substrate; laminating a layered laminate comprising a carrier film, an intermediate adhesive layer, and a textile top layer onto the top surface of the plane metal substrate, the carrier film contacting the further adhesive, thereby forming a laminated assembly.

2. Method according to claim 1, wherein the carrier film and the textile top layer of the layered laminate are dimensionally stable according to ASTM D1204 at a temperature of at least 150° C. during laminating, such that the dimensions of the layered laminate will not deviate by more than 5% from their original value.

3. Method according to claim 1, wherein the carrier film has been dimensionally stabilized by calendering the carrier film, preferably by calendering at a temperature of at least 150° C., preferably at least 160° C., such as between 170 and 210° C.

4. Method according to claim 1, wherein the carrier film has a thickness of between 30 and 200 μm, optionally between 60 and 120 μm.

5. Method according to claim 1, wherein the carrier film comprises a flame-retardant material.

6. Method according to claim 1, wherein the carrier film comprises a polyester, PET, PET-G, and/or PP.

7. Method according to claim 1, wherein the intermediate adhesive layer comprises a hot-melt adhesive.

8. Method according to claim 7, wherein the hot-melt adhesive is a polyester based adhesive, plastisol based adhesive, or polyurethane based adhesive.

9. Method according to claim 1, wherein the intermediate adhesive layer is flame-retardant.

10. Method according to claim 1, wherein the textile top layer has been heat stabilized at a temperature of between 150 and 200° C.

11. Method according to claim 1, wherein the textile top layer is flame retardant.

12. Method according to claim 1, wherein the textile top layer comprises an anti-stain agent.

13. A laminated assembly prepared by the method of claim 1.

14. A product comprising a laminated assembly according to claim 13.

15. The product according to claim 14, wherein the product is an indoor building envelope, interior partition wall element, noise shielding panel, or appliance panel.

16. Method according to claim 5, wherein the carrier film comprises polyvinyl chloride.

17. Method according to claim 7, wherein the hot-melt adhesive has a melting temperature of between 110 and 160° C., optionally between 130 and 140° C.

18. Method according to claim 10, wherein the textile top layer has been heat stabilized at a temperature of between 160 and 200° C., optionally between 180 and 200° C.

19. Method according to claim 11, wherein the textile top layer comprises an intrinsically flame-retardant fibre, optionally an intrinsically flame retardant polyester fibre.

20. Method according to claim 12, wherein the textile top layer comprises a flame-retardant anti-stain agent.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0073] FIG. 1: Schematic picture of a coil coating line.

[0074] FIG. 2: Schematic picture of a laminated assembly according to the invention.

DETAILED DESCRIPTION OF THE FIGURES

[0075] FIG. 1 depicts a typical coil coating line for carrying out a process according to the invention. In the embodiment shown, a coil 2 of a plane metal substrate 1 is unwound and transported through the line in transport direction 19. The substrate is degreased in degreasing zone 4, washed in washing zone 5, rinsed in rinsing zone 6, and subsequently passivated and dried in passivation zone 7 and drying zone 8, respectively. A primer 23 is applied by reverse roller coat in zone 9, cured by heating in primer heating zone 10, and cooled with water in primer cooling zone 11. In the depicted embodiment, an adhesive 24 and a back-coat 30 are applied simultaneously in adhesive and back-coat coating zones 12 and 13, respectively. Both the adhesive 24 and back-coat 30 are applied by reverse roller coat. Subsequent heating is performed in adhesive heating zone 14. The layered laminate 31 is laminated onto the metal substrate 1 in lamination zone 15. Subsequent cooling is performed by cooling with water in laminate cooling zone 16, followed by drying in laminate drying zone 17. The metal substrate is rewound onto coil 3.

[0076] FIG. 2 depicts an embodiment of a laminated assembly 21 according to the invention. Shown are the plane metal substrate 1, of which a first surface 32 is subsequently covered by a layer of optional metal substrate primer 23, further adhesive layer 24, and layered laminate 31. The second surface 33 is covered by a backing coating 30. Layered laminate 31 comprises in order layers 26, 25 and, and 28, i.e. carrier film 26, intermediate adhesive layer 25, and textile top layer 28.

Materials

[0077] Textile—An intrinsically flame retardant weaved polyester textile with a width of 1.5 m and a weight of 140 g/m.sup.2.

[0078] Rigid PVC—Commercially available rigid PVC with a thickness of 100 μm and a width of 1.5 m.

[0079] Intermediate adhesive—Web of a hot-melt copolyester with a melting temperature between 128 and 138° C., and a weight of 12-75 g/m.sup.2.

[0080] Adhesive—Commercially available polyester based adhesive.

Example 1

Layered Laminate

[0081] The textile was heat stabilized in a stenter device at a temperature of 180° C.

[0082] The PVC was calendered at a temperature of 160-210° C. over several cylinders resulting in a stabilized PVC sheet with a thickness of 100 μm.

[0083] The textile and PVC were laminated together with the intermediate hot-melt layer in between in a single passage at a temperature of about 140° C.

Laminated Assembly

[0084] A coil of galvanized steel was unwound, degreased and pre-treated by a passivant liquid; a primer was applied by using a reverse roll coating process typically at a line speed of m/min resulting in a film thickness of 8 μm. The primer was cured at a temperature of up to 232° C. for a total of 30 sec. Then the coil was cooled down by water and dried up. A polyester based adhesive was applied in a film thickness of 8 μm by using a reverse roll coating process at a line speed of 20 m/min, curing it up to 232° C. for a total of 30 sec. Then the layered laminate was laminated onto the adhesive with the PVC film contacting the adhesive immediately outside the oven. Then the coil was cooled down by water and dried up before being rewound.

[0085] The resulting product was tested with various procedures and was found to have the following properties:

TABLE-US-00001 Property Norm Result Resistance to bending EN 13523-7 ½ T (T-bend) Resistance to rapid ASTM D2794-93 No detachment or film deformation (Reap. 2010) breaking Salt spray fog resistance EN 13523-8/ASTM CRS Support: 200 hours B117-16 HDG Support: 500 hours

[0086] The invention furthermore relates to the following clauses: [0087] 1. Layered laminate comprising a carrier film, an intermediate adhesive layer, and a textile top layer, wherein the carrier film and the textile top layer are dimensionally stable at a temperature of at least 150° C., preferably at least 160° C. [0088] 2. Layered laminate according to clause 1, wherein the carrier film has been dimensionally stabilized by calendering the carrier film, preferably by calendering at a temperature of at least 150° C., preferably at least 160° C., such as between 170 and 210° C. [0089] 3. Layered laminate according to clause 1 or 2, wherein the carrier film has a longitudinal tensile strength of at least 30 MPa, most preferably at least 36 MPa. [0090] 4. Layered laminate according to any one of the preceding clauses, having a flexibility according to EN13523/7 of at most ½ T. [0091] 5. Layered laminate according to any one of the preceding clauses, wherein the carrier film has a longitudinal elongation at break of at least 100%, most preferably of at least 140%. [0092] 6. Layered laminate according to any one of the preceding clauses, wherein the carrier film has a thickness of between 30 and 200 μm, most preferably of between 60 and 120 μm. [0093] 7. Layered laminate according to any one of the preceding clauses, wherein the carrier film comprises a flame-retardant material, preferably wherein the carrier film comprises polyvinyl chloride. [0094] 8. Layered laminate according to any one of the preceding clauses, wherein the carrier film comprises a polyester, PET, PET-G, and/or PP. [0095] 9. Layered laminate according to any one of the preceding clauses, wherein the intermediate adhesive layer comprises a hot-melt adhesive. [0096] 10. Layered laminate according to clause 9, wherein the hot-melt adhesive has a melting temperature of between 110 and 160° C., preferably of between 130 and 140° C. [0097] 11. Layered laminate according to clause 9 or 10, wherein the hot-melt adhesive is a polyester based adhesive, plastisol based adhesive, or polyurethane based adhesive. [0098] 12. Layered laminate according to any one of the preceding clauses, wherein the intermediate adhesive layer is flame-retardant. [0099] 13. Layered laminate according to any one of the preceding clauses, wherein the textile top layer has been dimensionally stabilized at a temperature of between 150 and 200° C., preferably between 160 and 200° C., most preferably of between 180 and 200° C. [0100] 14. Layered laminate according to any one of the preceding clauses, wherein the textile top layer is flame retardant. [0101] 15. Layered laminate according to any one of the preceding clauses, wherein the textile top layer comprises an intrinsically flame-retardant fibre, preferably an intrinsically flame retardant polyester fibre. [0102] 16. Layered laminate according to any one of the preceding clauses, wherein the textile top layer comprises an anti-stain agent, preferably a flame-retardant anti-stain agent. [0103] 17. Method for applying textile to a carrier film, the method comprising laminating together a carrier film, an intermediate adhesive layer and a textile top layer, wherein the carrier film and the textile top layer are dimensionally stable at a temperature of at least 150° C., preferably at least 160° C., resulting in a layered laminate according to any one of clauses 1-16. [0104] 18. Method according to clause 17, wherein laminating is performed in at most 2 passages, and preferably in a single passage. [0105] 19. Method for applying textile to a plane metal substrate, the method comprising the steps of: [0106] providing a coiled plane metal substrate; [0107] unwinding the coiled plane metal substrate; [0108] applying a further adhesive layer onto a top surface of the plane metal substrate; [0109] laminating a layered laminate according to any one of clauses 1-16 onto the top surface of the plane metal substrate, the carrier film contacting the further adhesive, thereby forming a laminated assembly. [0110] 20. Laminated assembly obtainable by the method of clause 19, the laminated assembly comprising [0111] a plane metal substrate, [0112] a further adhesive layer, [0113] a layered laminate according to any one of the clauses 1-16. [0114] 21. Product comprising a laminated assembly according to clause 20. [0115] 22. Product according to clause 21, which is an indoor building envelope, interior partition wall element, noise shielding panel, or appliance panel.