Method of flexographically producing a faux galvanized metal finish on a substrate

A method of flexographically applying a faux galvanization coating to the surface of a coiled steel sheet, the method comprising:

• advancing a leading edge of a coiled metal substrate into the feed end of a flexographic coil coating line;
• advancing the metal substrate through at least one cleaning section within the coating line;
• advancing the metal substrate through a pretreatment station;
• advancing the metal substrate through a pretreatment oven within the coating line which raises the temperature of the substrate to approximately 300° F.;
• advancing the metal substrate into a flexographic roller with a flexographic roll pattern;
• applying with the flexographic roller a spangle pattern of polyvinylidene fluoride (PFDV) atop the metal substrate with the flexographic roller;
• advancing the metal coil substrate with spangle pattern into an oven;
• heating the metal coil substrate and applied PFDV pattern to a peak metal temperature in the range of about 455° F. to 475° F. and maintaining a residence time in the range of about 40 to 60 seconds;
• advancing the metal coil substrate with the applied PFDV pattern to a quench station to cool the metal coil substrate;
• advancing the quenched metal coil substrate with the applied PFDV pattern to a flexographic roller for application of a Fluoroethylene Vinyl Ether (FEVE) semi-transparent coating;
• flexographically applying a FEVE coating to the substrate over the PFDV pattern;
• advancing the metal coil substrate with the PFDV pattern and FEVE coating into an oven to achieve a substrate peak metal temperature in the range of about 470° F. to 490° F. to volatilize solvents from the applied FEVE coating;
• advancing the heated metal substrate with the PFDV pattern and FEVE coating to a quench station;
• and
• returning the coated metal substrate to a coiled configuration at the end of the flexographic coil coating line.

A system for flexographic production of a faux galvanized metal coil, the system comprising:

• a coiled metal substrate;
• a flexographic coating line with at least one flexographic roller for the application of at least one coating to the coiled metal substrate;
• a spangle pattern engraved onto the surface of the at least one flexographic roller;
• a quantity of polyvinylidene fluoride (PFDV) for application of a pattern to the coiled metal substrate;
• a quantity of fluoroethylene vinyl ether (FEVE) for application of a protective coating atop the PFDV pattern;
• a quantity of a pretreatment solution to prepare the metal substrate for application of the PFDV pattern;
• at least one oven to heat the substrate to a specified temperature;
• and
• at least one quench station to cool the substrate following heating in the at least one oven.

A coiled metal substrate with a faux galvanized surface appearance, the faux galvanized surface appearance not produced with galvanic action, the galvanized appearance made by a process comprising:

• advancing a leading edge of the coiled metal substrate into the feed end of a flexographic coil coating line;
• flexographically applying with a roller a spangle pattern of polyvinylidene fluoride (PFDV) atop the metal substrate with at least one flexographic roller of the coil coating line;
• advancing the PFDV spangle pattern coated metal substrate into a flexographic roller for application of a Fluoroethylene Vinyl Ether (FEVE) semi-transparent coating;
• and
• flexographically applying the FEVE coating to the substrate over the PFDV pattern.