# US 8,784,601 B1 · Applying polyester onto metal substrate

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- Number: US 8,784,601 B1
- Document ID: US8784601B1
- Status: Granted
- Kind: B1
- Application number: 13/759,538
- Filed: 2013-02-05
- Granted: 2014-07-22
- Earliest claimed: 2005-09-13
- Applicants: Mark V. Loen; James E. Velliky
- Inventors: Mark V. Loen; James E. Velliky
- Web page: https://patentgrep.com/patent/US8784601B1

## CPC

- B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 15/08: of synthetic resin
- B32B 15/18: comprising iron or steel {(B32B15/011, B32B15/012 and B32B15/013 take precedence)}
- B32B 27/08: of synthetic resin
- B32B 27/36: comprising polyesters
- B32B 37/003: {to avoid air inclusion}
- B32B 37/02: characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
- B32B 37/06: characterised by the heating method
- B32B 37/206: {Laminating a continuous layer between two continuous plastic layers}
- B32B 38/185: {combined with the cutting of one or more layers}
- B32B 37/04: characterised by the partial melting of at least one layer
- B32B 37/08: characterised by the cooling method
- B32B 38/105: {on edges}
- B32B 38/162: {Cleaning}
- B32B 39/00: Layout of apparatus or plants, e.g. modular laminating systems
- B32B 2305/30: Fillers, e.g. particles, powders, beads, flakes, spheres, chips
- B32B 2307/406: Bright, glossy, shiny surface
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/584: Scratch resistance
- B32B 2307/714: Inert, i.e. inert to chemical degradation, corrosion
- B32B 2309/02: Temperature
- B32B 2309/10: linear, e.g. length, distance, width
- B32B 2309/105: Thickness
- B32B 2309/14: Velocity, e.g. feed speeds
- B32B 2309/72: For measuring or regulating, e.g. systems with feedback loops
- B32B 2310/0445: using gas or flames (B32B2310/0427 takes precedence)
- B32B 2310/0812: using induction
- B32B 2310/0825: using IR radiation
- B32B 2311/00: Metals, their alloys or their compounds
- B32B 2367/00: Polyesters, e.g. PET, i.e. polyethylene terephthalate
- Y10T 156/1067: Continuous longitudinal slitting
- Y10T 156/108: Flash, trim or excess removal
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The present invention is a laminating process which is directed toward economical production methods for scalable amounts of production which develop properties suitable for a broad based product line. In particular, the product is capable of important key components of commercial properties such as adhesion, scratch resistance, chemical inertness, and bending without failure.

## Claims

### Claim 1

Processing steps for laminating a metal substrate with a thermoplastic polymer film to create desirable simultaneous commercial properties comprising:
a. uncoiling a metal substrate from a coil on a processing line,
b. wherein said metal substrate is flat rolled,
c. cleaning a first major side and a second major side of said metal surface,
d. increasing the surface energy of said first major side of said metal substrate by use of surface energy pretreatment equipment,
e. preheating said metal substrate to at least 200° F.,
f. preselecting a first film for bonding to said first major side, wherein said first film is either solid or molten,
g. pressing said first film onto said first major side by use of a first roll,
h. utilizing a first chemical bond for adhering said first film to said first major side thereby creating a metal polymer laminate,
i. wherein said first film comprises at least 50% thermoplastic polyester by weight,
j. wherein said polyester is PET, PBT, or a mixture of PET and PBT,
k. wherein said first film comprises at least one layer,
l. post treating said metal polymer laminate by heating said metal polymer laminate to at least the lowest melting point of any polymer in said first film, and
m. cooling said metal polymer laminate to below 150° F. for coiling into a finished coil,
n. wherein said cooling of said metal polymer laminate creates crystallinity in said first film according to a predetermined criterion, and
whereby said finished coil has said desirable simultaneous commercial properties comprising:
o. coating continuity of at least three metal thickness bending radius without metal exposure,
p. bonding of said first film onto said metal substrate of at least 43 ounces per inch after said cooling,
q. a minimum pencil hardness of 2B.

### Claim 2 (depends on 1)

The processing steps according to claim 1 wherein the following steps are done prior to said post treating of said metal polymer laminate:
r. increasing the surface energy of the second major side of said metal substrate by use of surface energy pretreatment equipment,
s. preselecting a second film for bonding to the second major side of said metal substrate,
t. pressing said second film onto the second major side by use of a second roll, wherein said second film is either solid or molten,
u. wherein said second roll is opposite of said first roll to create a roll nip,
v. utilizing a second chemical bond for adhering said second film to the second major side, and
w. wherein said second film comprises at least one layer.

### Claim 3 (depends on 1)

The processing steps according to claim 1 wherein said cooling is facilitated by utilizing a contact cooling roll, wherein said metal polymer laminate has predetermined surface finish properties.

### Claim 4 (depends on 1)

The processing steps according to claim 1 wherein said metal substrate is preprocessed before preheating by an item selected from the group consisting of:
i) conversion coated,
ii) pretreated, and
iii) coated with an organic primer.

### Claim 5 (depends on 2)

The processing steps according to claim 2 wherein said cooling is facilitated by utilizing a contact cooling roll, wherein said metal polymer laminate has predetermined surface finish properties.