• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The present invention relates to methods of manufacturing a weldable coated metal wire comprising a metal core surrounded by a coating, the coating comprising a zinc inner layer, a passivation layer and a sealing layer comprising the silicon compounds. The present invention further relates to a weldable coated metal wire and to structures comprising one or more weldable coated metal wires according to the present invention.
    公开号:BE1019329A3
    申请号:E201000281
    申请日:2010-05-07
    公开日:2012-06-05
    发明作者:Francis Emmers
    申请人:Merksteijn Quality Wire Belgium Van；
    IPC主号:
    专利说明:

    A METHOD FOR MANUFACTURING A COATED METAL WIRE FIELD OF THE INVENTION
    The present invention relates to methods for manufacturing a weldable coated metal wire that comprises a metal core surrounded by a coating, wherein the coating comprises a zinc inner layer, a passivation layer and a sealing layer with silicon compounds. The present invention further relates to a weldable coated metal wire and structures comprising one or more weldable coated metal wires according to the present invention.
    BACKGROUND OF THE INVENTION
    Metal wire is an important raw material in industry and construction. Various metals and metal alloys have the physical properties that are necessary to make a usable metal wire. The metals must in the first place be deformable and able to withstand a high tensile stress, qualities on which the usability of metal wires depends essentially. The metals suitable for metal wires that have an almost equal formability are platinum, silver, iron, copper, aluminum, steel and gold; and it is only from these metals and from some of their alloys with other metals, mainly brass and bronze, that metal wires are made.
    It is known from the prior art that metal wires can be provided with different metal coatings to add functionalities to the metal wires or to improve its properties. Known metal coatings on a metal wire are brass for adhesion with rubber, zinc or a zinc-aluminum alloy for corrosion resistance, nickel for heat resistance. Zinc coatings are often applied to metal wire through a hot immersion process. Passivating and sealing coatings are also often used to increase the corrosion resistance of the metal wire.
    Commonly used methods of applying coatings to metal objects are to immerse the objects in a coating solution or spray a coating solution onto the metal object. However, coating an object by immersing it in a bath takes a lot of time and such a method is not suitable for metal wires. Dip coating, where a metal object is immersed in a bath with the coating solution, is usually performed on large metal objects that require a uniform coating.
    Spraying a coating on a metal wire, on the other hand, provides a coating that is not evenly distributed over the wire. Also, problems such as foaming in the coating solution make the coating procedure difficult since the consistency of the coating could vary.
    Both spray coating and dip coating are also processes that are difficult to integrate into an in-line process. Dip coating requires a step in which the process is stopped to apply the coating, while spraying greatly influences the speed of the process.
    Especially when applying a complex coating comprising different coating layers on a metal wire, both dip coating and spray coating are unsuitable for inclusion in the in-line process where the metal wire is continuously transported through the various process steps at a constant speed.
    In view of the above, there remains a need in the art for a method of applying complex coatings to metal wires. Especially when the complex coatings comprise several layers of different chemistry, and when the application of the coating must be carried out in a continuous in-line operation with a minimum amount of materials and work and with a constant and predetermined quality of the coatings.
    The present invention has for its object to provide a method which enables the production of a coated metal wire, wherein a metal wire is subjected to at least three coating processes.
    More specifically, it is an object of the present invention to provide a method for manufacturing a coated metal wire of excellent quality. In addition, the coating applied to the metal wire according to the present invention provides the metal wire with specific advantageous features including improved corrosion resistance, good welding properties, and good formability.
    SUMMARY OF THE INVENTION
    The present invention generally relates to methods for manufacturing a coated metal wire. More specifically, the coated metal wire comprises a metal core (1) surrounded by a coating (2), the coating (2) comprising three layers: an inner layer (3), a central layer (4) and an outer layer layer (5) as indicated in Figure 1. The different layers of the coating are applied by passing a metal wire through a series of successive baths comprising coating solutions. By passing the metal wire through the series of successive baths comprising coating solutions, different coating layers can be applied to the metal wire, thereby providing the wire with improved properties.
    The inventors have determined that the methods of the present invention are methods that require only short contact times with the coating solutions, thereby providing a very fast coating method. Furthermore, the methods of the present invention provide a coated metal wire of excellent quality. The coated metal wire has the characteristic that it has a high corrosion resistance, whereby the service life of the coated metal wire or of constructions comprising the coated metal wire is extended. Another important property of the coated metal wire according to the present invention is that the coating of the wire does not affect the welding properties of the wire and improves the wear resistance of the wire. A further important aspect of the methods of the present invention is that the methods allow the introduction of dyes into the coating of the wire. The color of coated metal wires in the prior art was limited to a limited number of colors due to the fact that the introduction of a particular color, such as, for example, a black color, influences the welding characteristics of the coated metal wire. However, in the methods of the present invention, dyes can be introduced to provide coated metal wires with a wide variety of colors, including black coated metal wires, and this without affecting the other characteristics of the coated metal wire. Also, the coated metal wire according to the present invention remains flexible and malleable without disturbing the coating layer.
    The present invention provides methods for manufacturing a coated metal wire that is preferably weldable, comprising a metal core and a coating comprising a radial inner layer, a radial outer layer and a radial center layer located between said inner and outer layer, the methods comprising the steps of: (a) transporting a wire with a metal core through a galvanizing solution comprising zinc in a continuous manner, whereby a zinc coating layer is applied to said metal core wire and a galvanized metal wire is obtained is becoming; (b) transporting said galvanized metal wire obtained in step (a) through a passivation solution in a continuous manner, whereby a coating layer is applied to said galvanized metal wire and a passivated metal wire is obtained; and (c) continuously conveying said passivated metal wire obtained in step (b) through a sealing solution comprising a silicon compound and optionally dyes, whereby a sealing coating is applied to said passivated metal wire and said coated metal wire is obtained.
    The present invention also relates to a weldable coated metal wire comprising a metal core and a coating layer comprising a radial inner layer, a radial outer layer and a radial central layer located between said inner and outer layer, said radial inner layer being a zinc layer said radial center layer is a passivation layer and said radial outer layer is a sealing layer comprising silicon compounds and optionally dyes.
    The present invention also relates to the use of one or more weldable coated metal wires according to the present invention in a metal structure.
    These and further aspects and embodiments of the invention are further explained in the following chapters and in the claims, and are illustrated by non-limiting examples.
    BRIEF DESCRIPTION OF THE FIGURES
    Figure 1 schematically illustrates a cross-section of the coated metal wire according to the present invention.
    DETAILED DESCRIPTION OF THE INVENTION
    Before describing the current methods and devices used in the invention, it is to be understood that this invention is not limited to specific methods, components or devices described, since such methods, components and devices may, of course, vary. It is also to be understood that the terminology used herein is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
    Unless otherwise specified, all technical and scientific terms used herein have the same meaning as generally understood by one skilled in the art to which this invention belongs. Although in practice or in testing the present invention, all methods and materials similar to or equivalent to those described herein can be used, the preferred methods and materials are now described.
    As used herein, the singular forms "one," "the," and "the" include both the singular and the plural of the referenced unless the context clearly dictates otherwise.
    The terms "comprising", "includes" and "included" as used herein are synonymous with "including", "containing" or "contains", and are inclusive or open and do not include additional, unnamed members, elements or process steps.
    The terms "comprising", "includes" and "included" also include the term "consisting of".
    Naming numeric ranges by endpoints includes all numbers and fractions that are within the respective ranges, as well as the endpoints mentioned.
    The term "about" as used herein when referring to a measurable value such as a parameter, an amount, a duration, and the like, will include variations of +/- 10% or less, preferably +/- 5% or less, more preferably +/- 1% or less, and even more preferably +/- 0.1% or less of the specified value, insofar as such variations apply to the disclosed invention. It must be understood that the value to which the provision "roughly" refers is also specific and preferably revealed.
    All documents quoted in the current specification are hereby incorporated by reference in their entirety.
    Unless otherwise specified, all terms used in the disclosure of the invention, including technical and scientific terms, have the meaning as generally understood by those skilled in the art to which this invention belongs. As a further aid, definitions for the terms used in the description are included to better appreciate the principles of the present invention.
    It is an object of the present invention to avoid the disadvantages of the prior art.
    The present invention generally relates to methods for manufacturing a coated metal wire.
    The term "metal wire" as used herein refers to a single, usually cylindrical, metal wire used to bear a mechanical load.
    More specifically, the coated metal wire comprises a metal core (1) surrounded by a coating (2), the coating (2) comprising three layers: an inner layer (3), a central layer (4) and an outer layer ( 5) as shown in Figure 1. The different layers of the coating are applied by passing a metal wire through a series of successive baths comprising coating solutions. By passing the metal wire through the series of successive baths comprising coating solutions, different coating layers can be applied to the metal wire, whereby the wire acquires improved properties.
    The inventors have determined that the methods of the present invention are methods that require only short contact times with the coating solutions, thereby providing a very fast coating method. Furthermore, the methods of the present invention provide a coated metal wire of excellent quality. The coated metal wire has the characteristic that it has a high corrosion resistance, as a result of which the service life of the coated metal wire, or of constructions comprising the coated metal wire, is extended. Another important property of the coated metal wire according to the present invention is that the coating of the wire does not affect the welding properties of the wire and improves the wear resistance of the wire. Another important aspect of the methods of the present invention is that the methods allow the introduction of dyes into the coating of the wire. While the color of coated metal wires was limited in the prior art to a limited number of colors due to the fact that the introduction of a particular color, such as, for example, a black color, influences the welding characteristics of the coated metal wire. In the methods of the present invention, dyes can be introduced whereby coated metal wires are provided with a wide variety of colors, including black coated metal wires, and this without affecting the other characteristics of the coated metal wire. Also, the coated metal wire according to the present invention remains flexible and malleable without disturbing the coating layer.
    The present invention provides methods for manufacturing a coated metal wire that is preferably weldable, comprising a metal core and a coating comprising a radial inner layer, a radial outer layer and a radial center layer located between said inner and outer layer, wherein the method comprises the following steps: (a) transporting a wire with a metal core through a galvanizing solution comprising zinc in a continuous manner, whereby a zinc coating layer is applied to said wire with metal core and a galvanized metal wire is obtained ; (b) transporting said galvanized metal wire obtained in step (a) through a passivation solution in a continuous manner, whereby a coating layer is applied to said galvanized metal wire and a passivated metal wire is obtained; and (c) continuously conveying said passivated metal wire obtained in step (b) through a sealing solution comprising a silicon compound and optionally dyes, whereby a sealing coating is applied to said passivated metal wire and said coated metal wire is obtained.
    As used herein, the term "coated metal wire" refers to a metal wire that includes a metal core surrounded by a coating. The metal wire refers to a single metal wire that can be used for a large number of applications. In fact, the metal wire is an important raw material in industry and construction.
    The metal wire can have any cross section such as round, square, rectangular, oval or half oval cross sections. The metal wires according to the present invention can be selected within a large diameter range that is between 0.1 mm and 50 mm, preferably between 0.5 mm and 30 mm and more preferably between 2 mm and 16 mm. The coating according to the present invention has a thickness between 0.1 µm and 50 µm, preferably between 0.5 µm and 30 µm and more preferably between 2 µm and 16 µm.
    The material of the metal core can be any type of metal or metal alloy, such as platinum, silver, iron, copper, aluminum, gold, steel, brass or bronze. Preferably the material of the metal core is steel or iron. When a steel core is used, the steel can have a low or high carbon content.
    According to the present invention, the inner layer of the coating refers to the portion of the coating at the interface with the metal core. The outer layer of the coating refers to the portion of the coating that is intended to be on the outside of the coated metal wire. The central layer of the coating refers to the portion of the coating that is located between the inner and outer layers.
    The methods according to the invention comprise at least three steps through which a metal wire is guided through a bath containing a coating solution or transported. The metal wire is transported along a predetermined route in a continuous manner, preferably at a speed in the range of about 10 to about 500 m / min, more preferably at a speed in a range of about 25 to about 250 m / min and most preferably a speed in a range of about 50 to about 200 m / min. The transport speed of the metal wire can be, for example, about 50, 60, 70, 75, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190 or 200 m / min. Preferably, the transport speed of the metal wire in the methods of the present invention remains substantially constant throughout the entire process. This refers to the continuous way in which the metal wire is guided through each of the coating solutions.
    Therefore, in a particular embodiment, the methods of the present invention determine that said metal wire is conveyed in at least steps (a), (b) and (c) at a speed in the range of about 10 to about 500 m / min.
    The methods of transporting the metal wire through the process of the present invention can refer to any type of transport methods known in the art. For example, the device for transporting the metal wire comprises at least one device for feeding the metal wire to a series of coating baths and a device for receiving the coated metal wire. Depending on the transport speed of the metal wire and the distance that the wire travels through each of the coating solutions, the residence time of the metal wire in each of the coating solutions can be calculated.
    In one of the steps of the methods according to the present invention, the wire with a metal core is transported or guided in a continuous manner through a galvanizing solution comprising zinc, whereby a zinc coating layer is applied to said wire with metal core and a galvanized one metal wire is obtained. According to the methods of the present invention, this process step is referred to as the electroplating step wherein a zinc coating layer is applied to the metal core wire. This galvanization step can take place using any of the galvanization methods known in the art, including hot-dip galvanization or electrolytic galvanization with zinc. The methods of the present invention preferably use electrolytic galvanization.
    In hot-dip galvanization, the metal core wire is passed through a molten zinc bath at a temperature of about 460 ° C. When exposed to the atmosphere, pure zinc reacts with oxygen to form zinc oxide, which further reacts with carbon dioxide to form zinc carbonate that protects the metal core from corrosion. When using hot-dip galvanization, the galvanized metal wire can first be subjected to a polishing step before applying the other coating layers to the galvanized metal wire. This polishing step can include a wire drawing run. Wire drawing is a metalworking process used to reduce the diameter of a wire or for polishing purposes by pulling the wire through a single die or through a series of dies. The drawing is preferably carried out at room temperature, but for large wires it can be carried out at elevated temperatures.
    Electrolytic galvanization can take place through either a basic or an acid electrolytic galvanization process in which the metal wire is first charged with an electrical charge before the wire is passed through the galvanizing solution comprising zinc. Electrolytic galvanization does not require elevated temperatures of the galvanization solution, the temperature of the galvanization solution is between 60 and 75 ° C.
    In a basic electrolytic galvanization process, the electrolyte is a basic solution that comprises zinc. For example, a zinc-containing basic solution comprising, for example, NaOH and ZnO can be used for this process. For an acid electrolytic galvanization process, the electrolyte is an acidic solution comprising zinc. For example, an acidic galvanizing solution may include zinc sulfide or zinc chloride. Other additives can be added to the electroplating solution to improve the quality of the coating.
    While a zinc coating generally forms a physical barrier against corrosion, the inventors have found that an electrolytic galvanization confers additional benefits to the applied zinc coating. It has been found that the coating can be applied more easily to the metal wire without requiring extensive maintenance of the installation. Furthermore, the thickness of the zinc coating can be controlled more precisely when electrolytic galvanization is used. It was also found that the zinc coating has a greater adhesion to the metal core and also that it improves the adhesion of the next coating layer. The inventors have also found that an electrolytic galvanization process provides a high quality galvanized metal wire that does not require the wire drawing step.
    As used herein, the term "galvanized metal wire" refers to a metal wire that includes a metal core surrounded by a zinc coating. The thickness of the zinc coating layer is between 0.1 µm and 50 µm, preferably between 1 µm and 25 µm and more preferably between 2 µm and 15 µm.
    In another step of the methods according to the present invention, the galvanized metal wire is transported or guided in a continuous manner through a passivation solution. This process step provides a coating layer on said galvanized metal wire, whereby a passivated metal wire is obtained. According to the methods of the present invention, this process step is referred to as the passivation step wherein a coating layer is applied to the galvanized metal wire. This passivation step can take place using all passivation methods known in the art, and preferably by passing the galvanized metal wire through a passivation solution. The passivation solution typically comprises compounds such as cobalt, trivalent chromium, hexavalent chromium, iron, nickel, molybdenum, manganese, lanthanum, lanthanide, or mixtures thereof, dissolved in solutions such as chromates, molybdates, etc. Additionally, the passivation solution can optionally further halide ions, including fluoride, chloride, and bromide ions, as well as one or more compatible wetting agents. Preferably, the passivation solution comprises trivalent chromium ions, cobalt ions and nitrate ions.
    The passivation methods refer to methods for making the galvanized metal wire passive whereby the reactivity of a chemically active metal surface is reduced by immersion in a passivation solution. The passivation solution oxidizes and dissolves all impurities on the surface of the galvanized metal wire, thereby removing all impurities. Passivation leads to the spontaneous formation of a hard non-reactive surface film that inhibits further corrosion.
    As used herein, the term "passivated metal wire" refers to a metal wire comprising a metal core surrounded by a zinc inner layer surrounded by a passivation layer. The thickness of the passivation layer is between 50 nm and 750 nm, preferably between 100 nm and 600 nm, more preferably between 150 nm and 500 nm, and more preferably between about 200 nm and 400 nm.
    In a particular step of the methods of the present invention, the passivated metal wire is transported or passed through a sealing solution comprising a silicon compound and optionally dyes, whereby a sealing coating is applied to said passivated metal wire and the coated metal wire of the invention is obtained. According to the methods of the present invention, the process step is referred to as the sealing step in which a layer is applied to the passivated metal wire. This sealing step can be performed by any of the sealing methods known in the art, and preferably by guiding the passivated metal wire through a sealing solution.
    The sealing methods refer to methods for providing a coated metal wire with an outer layer for resisting aggressive environments. The sealing coating gives the coated metal wire a further coating for corrosion resistance. This can be explained by the closed structure of the sealing layer and by the intrinsic inert properties of the sealing agent.
    In a specific embodiment, the present invention provides methods for manufacturing a weldable coated metal wire wherein the residence time of said passivated metal wire in said passivation solution according to step (c) is between 15 and 60 seconds, and preferably between 25 and 35 seconds, and more preferably about 30 seconds.
    In contrast to the prior art methods where the coating with a typical sealing solution requires typical contact times of more than 2 minutes, the methods of the present invention provide a high quality sealing coating on the passivated metal wire, and only after a short contact time between the sealing solution and the passivated metal wire.
    In a particular embodiment, the present invention refers to methods of the invention wherein the temperature of said sealing solution is at room temperature or is preferably between 15 ° C and 35 ° C. The temperature of said sealing solution can be, for example, about 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34 or 35 ° C. The pH of said sealing solution is between 8.0 and 10.0, more preferably between 8.5 and 9.5, and most preferably between 8.9 and 9.3.
    In a particular embodiment, the present invention provides methods for producing a weldable coated metal wire wherein said coating solution comprises silicon compounds. Said silicon compounds are preferably organic and / or inorganic silicon compounds wherein said silicon compound is preferably selected from the group comprising a silicate such as a sodium silicate, potassium silicate, magnesium silicate, cobalt silicate, sodium metasilicate, potassium metasilicate, calcium metasilicate, silicic acid, or enasilicate acid said organic silicon compound is selected from the group comprising a silicon compound comprising carbon-silicon bonds such as organosilanes, siloxides, silyl halides, silyl hydrides, silenes, silols and / or hyper-coordinated silicon and preferably C1 to C6 alkylsilanes, silicon oil, ethyl silicate, silyl acetals, silanols, siloxanes, polysiloxanes, silyl ethers, trimethylsilyl chloride, dichloromethylphenylsilane, dimethylchlorosilane, methyltrichlorosilane, (4-aminobutyl) diethoxymethylsilane, trichloro (chloromethyl) silane, trichloro (dichlorophenyl) silane, trichloroethylsil enylsilane and / or trimethylchlorosilane.
    More preferably, said sealing solution is SurTec 556 RT ™ (Suretec), Plus® L, VL, ML, M or XL sealing coatings (Dacral), Sealer 300 W (Atotech) or Sealer 350 W (Atotech).
    More preferably, according to a particular embodiment, the present invention relates to methods according to the present invention wherein said sealing solution contains silicon compounds in a concentration that is between 0.01 g / L and 10 g / L, preferably between 0.05 g / L and 5 g / L, more preferably between 0.1 g / L and 5 g / L.
    In a particular embodiment, the present invention relates to methods according to the present invention wherein said coated metal wire obtained in step (c) is subjected to a heat treatment. The heat treatment refers to any type of treatment contemplated by those skilled in the art that could raise the temperature of the coated metal wire, such as exposing the coated metal wire to an external heat source such as an oven or a flame, or any other heat treatment such as preferably induction, electrical heating or heat treatment with the aid of a laser beam.
    In a further embodiment of the present invention, the sealing solution is a solution comprising silicon compounds and dyes. By adding one or more dyes such as pigments to the sealing solution, the coated metal wire according to the invention can be colored in any desired color. This results in a coated metal wire that is colored and that at the same time retains the specific characteristics of the coated metal wire that is colored and which at the same time retains the specific characteristics of the coated metal wire such as corrosion resistance, weldability, wear resistance and deformability.
    Both inorganic and organic pigments can be used as colorants. The colored metal wires obtained according to the present invention can refer to the entire visible spectrum, from violet to red. Luminescent pigments can also be added.
    With the addition of colorants colors such as black, silver, blue, yellow, olive green, green and red can be obtained.
    Colored coated metal wires according to the present invention are also very suitable to be used for fencing since they give a nice decorative aspect and at the same time an improved corrosion resistance. For example, they can be used as barbed wire, for knotted fences, for welded fences, ...
    Depending on the desired color, the dyes can also be applied in a separate color solution through which the passivated metal wire is transported.
    In a specific embodiment, the present invention provides a method according to the present invention wherein the residence time of said passivated metal wire in said sealing solution is between 0.5 and 10 seconds, preferably between 0.75 and 5 seconds and preferably between 1 and 2 seconds.
    After applying the sealing coating layer, the coated metal wire according to the invention is obtained. As used herein, the term "coated metal wire" refers to a metal wire that comprises a metal core surrounded by a zinc inner coating layer, which is surrounded by a central layer of a passivation coating comprising trivalent chromium and cobalt, said central coating layer being surrounded is through a sealing coating layer. The thickness of the sealing coating layer is between 50 nm and 750 nm, preferably between 100 nm and 600 nm, more preferably between 150 nm and 500 nm and more preferably between about 200 nm and 400 nm.
    In a further specific embodiment, the present invention refers to methods according to the present invention wherein the wire with metal core is transported from a starting position where a roll of said wire with metal core is unwound, along a predetermined route through various treatment baths containing treatment solutions, to a receiving end position where said coated metal wire is rolled up.
    By guiding the metal wire from the initial position to the receiving end position through the various treatment steps of the present invention, an in-line process is generated that provides fast and inexpensive methods of coating a metal wire.
    With the methods of the present invention, additional process steps of the metal wire can be included such as degreasing, rinsing, biting, wire drawing and / or drying. The methods of the present invention result in a simplified process. Applying the coating according to the present invention can be carried out in a continuous, in-line process with other process steps such as degreasing, rinsing, biting, wire drawing and / or drying. By using a continuous process, the production costs are considerably reduced.
    A degreasing process typically takes place at the beginning of the process, after unwinding of the metal wire. Degreasing can be carried out by methods well known in the art and, for example, by using a solution of sodium hydroxide and surfactants. The flushing can be performed before and after the galvanizing process, and after the passivation process. The rinsing can be performed by methods well known in the art and, for example, by using an aqueous solution. Biting refers to a process step in which the wire is subjected to an acid solution just before the passivation step. The stripping can be carried out by methods well known in the art and, for example, by using an acid solution of nitric acid, sulfuric acid, hydrochloric acid, phosphoric acid, boric acid, hydrogen fluoride, hydrobromic acid or any other acid known in the art. The drying process can be carried out at the end of the coating process, just before rolling up the coated metal wire. The drying of the metal wire can be carried out by methods well known in the art.
    In a specific embodiment of the present invention, the methods for manufacturing a coated metal wire according to the present invention comprise the further steps of: (1) unwinding a wire with a metal core from a roll; (2) degreasing said metal core wire; (3) spooling said wire with metal core; (4) electroplating said wire with metal core, thereby providing a galvanized metal wire; (5) rinsing said galvanized metal wire; (6) biting said galvanized metal wire; (7) passivating said galvanized metal wire, thereby providing a passivated metal wire; (8) spooling said passivated metal wire; (9) sealing said passivated metal wire, thereby providing a coated metal wire; and; (10) drying said coated metal wire.
    According to a particular embodiment, the present invention relates to a weldable coated metal wire obtained by or obtainable by any of the methods of the present invention.
    The present invention also relates to a weldable coated metal wire which comprises a metal core and a coating layer, which comprises a radial inner layer, a radial outer layer and a radial central layer located between said inner and outer layer, said radial inner layer is a zinc layer, said radial central layer is a passivation layer and said radial outer layer comprises silicon compounds and optionally dyes.
    In a particular embodiment, the present invention relates to a weldable coated metal wire according to the present invention, wherein the thickness of said radial inner layer is between 0.1 and 50 µm, preferably between 1 µm and 30 µm, preferably between 1 µm and 25 µm and more preferably between 2 µm and 15 µm, wherein the thickness of said radial center layer is between 50 and 750 nm, preferably between 100 nm and 600 nm, more preferably between 150 nm and 500 nm and with more preferably between about 200 nm and 400 nm and / or wherein the thickness of said radial outer layer is between 50 and 750 nm, preferably between 100 nm and 600 nm, more preferably between 150 nm and 500 nm and more preferably between about 200 nm and 400 nm. The coated metal wire according to the present invention can be provided in any color, depending on the dyes or pigments in the central and / or outer layer. The inventors have also noted for the coated metal wire according to the present invention that the applied coating also provides a better UV resistance to the metal wire. Where typically passivated articles gradually lose their color upon exposure to light, it has been found that the coated metal wire of the present invention retains its color. For example, it is common knowledge that black passivated objects gradually lose their color and become olive-colored over time. This effect was not observed for the coated metal wire according to the present invention.
    In a particular embodiment, the present invention relates to a weldable coated metal wire according to the present invention, wherein said radial inner layer comprises zinc and / or wherein said radial central layer has a silicon content between 93.00% and 100% and optionally a dye content of less than 7.00%.
    In another embodiment, the present invention relates to a weldable coated metal wire according to the present invention, wherein said radial center layer contains a silicon compound.
    In a further embodiment, the present invention relates to a weldable coated metal wire according to the present invention, wherein said metal core is made of steel.
    The present invention also relates to a structure comprising one or more coated metal wires according to the present invention. Said structure comprising one or more coated metal wires according to the present invention refers to a structure that can be used in the construction, the automotive industry, presentation screens, food industry, medical and / or laboratory products, horticulture, ventilation, lighting and other industries. Non-limiting examples of such structures include fencing, gates, woven fabrics, car bodies and other car components, U-bolts, slip rings, mounting eyes and rings, conductors, exhaust brackets, headrests, operating rods and other metal wire products such as displays, racks, nets, lampshades, frames, hooks, brackets, clips, rings and springs.
    The weldable coated metal wire according to the present invention can also be used to make a multi-stranded wire that comprises a bundle of such coated metal wires. A multi-stranded wire is also referred to as a wire cable.
    The coated metal wires according to the present invention have been found to require very short contact times between the metal wire and the coating solutions. Furthermore, the coating provides the metal wire with increased corrosion resistance, wear resistance and flexibility while still maintaining good weldability. The weldability of a material refers to its ability to be welded. Many metals can be welded, but some are easier to weld than others. The weldability greatly influences the welding quality and is an important factor in choosing which welding method would be used. The coated metal wires from the prior art often show that by applying a coating to the metal wire the weldability decreases. With the coated metal wire according to the present invention, the weldability is not affected by the presence of the coating.
    Dyes can also be added to the sealing layer allowing the coated wires to have a specific color, and without affecting the other characteristics of the bagable coated metal wire.
    The present invention also relates to the use of one or more weldable coated metal wires according to the present invention in a metal structure.
    More preferably, the present invention relates to the use of one or more coated metal wires according to the present invention in a metal structure for use in construction and / or the automotive industry.
    EXAMPLES
    Coated metal wires were made according to the methods of the present invention and various characteristics were measured. A weldable coated metal wire with a zinc coating of 15 µm, a passivation coating with a thickness of 300 nm and a sealing coating with a thickness of 300 nm was used to test the corrosion resistance, heat resistance and climate resistance.
    The corrosion resistance of the coated metal wire according to the present invention was measured using a neutral salt spray test (ISO 9227). The coated metal wire according to the present invention exhibited a corrosion resistance of about 200 hours in this test.
    The heat resistance of the coated metal wire according to the present invention was measured by subjecting the coated metal wire to 200 ° C for 30 minutes and then cooling the metal wire in water at 20 ° C. This test showed that the coating was highly heat resistant and no fractures or cracks were observed in the coating.
    The climate resistance of the coated metal wire according to the present invention was measured by subjecting the coated metal wire to continuously changing conditions of temperature and water saturation. No cracks or cracks were observed in the coating during this test.
    It was also found that the coated metal wire of the present invention has good welding properties, and during a bending test where the coated metal wire of the present invention was spiraled around its axis, the coating remained intact.
    权利要求:
    Claims (15)
    [1]
    A method for manufacturing a coated metal wire comprising a metal core and a coating comprising a radial inner layer, a radial outer layer and a radial central layer located between said inner and outer layer, the method comprising the following steps: (a) transporting a wire with a metal core through a galvanizing solution comprising zinc in a continuous manner, whereby a zinc coating layer is applied to said wire with a metal core and a galvanized metal wire is obtained; (b) transporting said galvanized metal wire obtained in step (a) through a passivation solution in a continuous manner, whereby a coating layer is applied to said galvanized metal wire and a passivated metal wire is obtained; (c) transporting said passivated metal wire obtained in step (b) in a continuous manner through a sealing solution comprising a silicon compound and optional dyes, whereby a sealing coating is applied to said passivated metal wire and said coated metal wire is obtained.
    [2]
    Method according to claim 1, wherein the residence time of said passivated metal wire in said sealing solution according to step (c) is between 15 and 60 seconds and preferably between 25 and 35 seconds and more preferably 30 seconds.
    [3]
    The method according to claim 1 or 2, wherein the temperature of said sealing solution is between 15 ° C and 35 ° C and the pH of said sealing solution is between 7.5 and 9.5.
    [4]
    The method according to any of claims 1 to 3, wherein said silicon compound is an organic or inorganic silicon compound.
    [5]
    The method according to any of claims 1 to 4, wherein said sealing solution comprises silicon compounds in a concentration ranging between 0.01 g / L and 10 g / L.
    [6]
    The method according to any of claims 1 to 5, wherein said coated metal wire obtained according to step (c) is subjected to a heat treatment.
    [7]
    The method according to any of claims 1 to 6, wherein said metal wire is conveyed in at least steps (a), (b) and (c) at a speed ranging from about 10 to about 500 m / min.
    [8]
    A weldable coated metal wire comprising a metal core and a coating layer comprising a radial inner layer, a radial outer layer and a radial center layer located between said inner and outer layer, said radial inner layer being a zinc layer, said radial center layer is a passivation layer and said radial outer layer is a sealing layer comprising silicon compounds and optionally dyes.
    [9]
    A weldable coated metal wire according to claim 8, wherein the thickness of said radial inner layer is between 1 and 30 µm, wherein the thickness of said radial central layer is between 100 and 500 nm and / or wherein the thickness of said radial outer layer is between 100 and 500 nm.
    [10]
    A weldable coated metal wire according to claim 8 or 9, wherein said radial inner layer comprises zinc and / or wherein said radial central layer has a silicon content that is between 93.00% and 100%, and optionally a dye content of less than 7, 00%.
    [11]
    A coated metal wire according to any of claims 9 to 10, wherein said radial central layer comprises a silicon compound.
    [12]
    A coated metal wire according to any of claims 9 to 11, wherein said metal core is made of steel.
    [13]
    A metal structure comprising one or more coated metal wires according to any of claims 9 to 12.
    [14]
    Use of one or more coated metal wires according to any of claims 9 to 12 in a metal structure.
    [15]
    Use of one or more coated metal wires according to claim 14 in a metal structure for use in the construction and / or automotive industry.
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    同族专利:
    公开号 | 公开日
    EP2371984A1|2011-10-05|
    引用文献:
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    法律状态:
    2018-04-25| MM| Lapsed because of non-payment of the annual fee|Effective date: 20170531 |
    优先权:
    申请号 | 申请日 | 专利标题
    EP10159047|2010-04-02|
    EP10159047A|EP2371984A1|2010-04-02|2010-04-02|Method for producing a coated metal wire|
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