• 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 a method of manufacturing a 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. The present invention further relates to a coated metal wire and to structures comprising one or more coated metal wires according to the present invention.
    公开号:BE1019633A3
    申请号:E201000019
    申请日:2010-01-14
    公开日:2012-09-04
    发明作者:Francis Emmers
    申请人:Merksteijn Quality Wire Nv Van；
    IPC主号:
    专利说明:

    METHOD FOR MANUFACTURING A COATED METAL WIRE
    FIELD OF THE INVENTION
    The present invention relates to a method for manufacturing a coated metal wire which comprises a metal core surrounded by a coating, wherein the coating comprises a zinc inner layer, a passivation layer and a sealing layer. The present invention further relates to a coated metal wire and structures comprising one or more coated metal wires according to the present invention.
    BACKGROUND OF THE INVENTION
    A metal wire refers to a single, usually cylindrical metal wire that is used to withstand a mechanical load. The 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 wire. The metals must in the first place be deformable and able to withstand a high tensile stress, qualities on which the utility of the wire depends essentially. The metals suitable for the wire 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 the wire is made.
    The prior art has determined that metal wires can be provided with various metal coatings to add functionalities to the metal wire or to improve its properties. Well-known metal coatings on a metal wire are brass for adhesion with rubber, zipk or a zinc-aluminum alloy for corrosion resistance, nickel for heat resistance. Zinc coatings are often applied to the metal wire by a hot immersion method. 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 foam formation in the coating solution make the coating procedure difficult since the consistency of the coating would vary.
    Both spray coating and dip coating are also methods that are difficult to integrate into an in-line method. 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 to a metal wire that comprises different coating layers, both dip coating and spray coating are unsuitable for inclusion in the in-line process in which 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 methods.
    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 a method 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 (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 guiding 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 method of the present invention is a method that requires only short contact times with the coating solutions, thereby providing a very fast coating method. Furthermore, the method of the present invention provides 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. Another important aspect of the method of the present invention is that the method allows 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 method 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.
    In particular, the present invention provides 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, 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) continuously transporting said galvanized metal wire obtained in step (a) chlorine to a passivation solution comprising trivalent chromium ions, cobalt ions and nitrate ions, 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 synthetic polymer and a non-ionic surfactant, 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 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, said radial inner layer being a zinc layer said radial central layer is a passivation layer comprising trivalent chromium and cobalt and said radial outer layer is a sealing layer comprising a synthetic polymer.
    The present invention also relates to a structure comprising one or more coated metal wires according to the present invention.
    These and further aspects and embodiments of the invention are further explained in the following chapters and in the claims and also 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 the current working method and the. 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" and "includes" as used herein are synonymous with "including", "containing" or "contains", and are inclusive or open and do not exclude additional, unnamed members, elements or process steps .
    The terms "comprising" and "includes" 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 a method 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 ( 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 guiding 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 method of the present invention is a method that requires only short contact times with the coating solutions, thereby providing a very fast coating method. Furthermore, the method of the present invention provides 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 structures 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 method of the present invention is that the method allows 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 method 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.
    In particular, the present invention provides a method of 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, 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) in a continuous manner through a passivation solution comprising trivalent chromium ions, cobalt ions and nitrate ions, 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 synthetic polymer and a non-ionic surfactant, 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 sit 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 method according to the invention comprises 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 remains of the metal wire in the method according to the present invention substantially constant throughout the entire method. This refers to the continuous way in which the metal wire is guided through each of the coating solutions.
    Therefore, the method of the present invention determines that said metal wire is conveyed at a speed in the range of about 10 to about 500 m / min.
    The method of transporting the metal wire through the method 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 method 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 a metal core and a galvanized metal wire is obtained. According to the method of the present invention, this process step is referred to as the electroplating step in which 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. The method of the present invention preferably uses 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 method 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 by either a basic or an acid electrolytic galvanization method 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 method, the electrolyte is a basic solution comprising 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 method, the electrolyte is an acid solution comprising zinc. For example, an acidic electroplating 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 method 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 method according to the present invention, the galvanized metal wire is continuously transported or passed through a passivation solution comprising trivalent chromium ions, cobalt ions and nitrate ions, whereby a coating layer is applied to said galvanized metal wire and a passivated one metal wire is obtained. According to the method of the present invention, this process step is referred to as a passivation step in which a coating layer is applied to the galvanized metal wire. This passivation step can take place with the help of all passivation methods known in the art and preferably by passing the galvanized metal wire through a passivation solution.
    The passivation method refers to a method 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.
    In a specific embodiment, the present invention provides a method for manufacturing a coated metal wire wherein the residence time of said galvanized metal wire in said passivation solution is between 15 and 60 seconds, preferably between 25 and 35 seconds and preferably about 30 seconds.
    In contrast to the prior art methods where the coating with a typical passivation solution requires typical contact times of more than 2 minutes, the method according to the present invention provides an excellent quality passivation coating on the galvanized metal wire, and only after a short contact time between the passivation solution and the galvanized metal wire.
    In another embodiment, the present invention refers to a method according to the invention wherein the temperature of said passivation solution is between 40 ° C and 100 ° C, preferably between 50 ° C and 90 ° C and more preferably between 60 ° C and 80 ° C. The temperature of said passivation solution can be, for example, about 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79 or 80 °. Be C. The pH of said passivation solution is between 1.0 and 3.0, more preferably between 1.3 and 2.5 and most preferably between 1.6 and 1.8.
    In the method of the present invention, the passivation solution comprises trivalent chromium ions, cobalt ions and nitrate ions. Preferably, said passivation solution is an aqueous solution. Preferably, the passivation solution according to the present invention is free or substantially free of hexavalent chromium. Since hexavalent chromium (Cr (VI)) is a toxic and carcinogenic compound, the use of Cr (VI) is avoided in the passivation solution according to the present invention.
    More preferably, the present invention according to another embodiment relates to a method according to the present invention wherein said passivation solution comprises trivalent chromium ions in a concentration ranging between 1 g / L and 100 g / L, preferably between 5 g / L and 75 g / L, more preferably between 10 g / L and 60 g / L, more preferably between 15 g / L and 50 g / L and most preferably between 20 g / L and 45 g / l. Said passivation solution may further comprise cobalt ions in a concentration that is between 0.005 g / L and 5 g / L, preferably between 0.01 g / L and 3 g / L and more preferably between 0.02 g / L and 2, 5 g / l.
    The passivation solution of the present invention can comprise trivalent chromium ions in a concentration of about 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37 , 38, 39, 40, 41, 42, 43, 44, or 45 g / L and cobalt ions in a concentration of about 0.02, 0.05, 0.075, 0.1, 0.2, 0.25, 0 5, 0.75, 1.0, 1.25, 1.5, 1.75, 2.0, 2.25 or 2.5 g / L.
    In a preferred embodiment of the present invention, the passivation solution of the present invention is an aqueous solution comprising compounds such as chromium trichloride, chromium nitrate and / or cobalt nitrate. Preferably, said passivation solution comprises between 10% and 20% chromium trichloride, between 1% and 3% chromium nitrate and between 0.01% and 1% cobalt nitrate. More preferably, said passivation solution is SurTec 694 ™ and / or SurTec 694A ™.
    In a further embodiment, the present invention refers to a method according to the present invention wherein said passivation solution comprises dyes. By adding one or more dyes such as pigments to the passivation solution, the coated metal wire according to the invention can be colored. 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 such as corrosion resistance, weldability, wear resistance and formability.
    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, blue, yellow, olive green, green and red can be obtained. For example, to obtain a metal wire with a black color, SurTec 694 ™ and / or SurTec 694A ™ can be used as passivation solution.
    Colored coated metal wires according to the present invention are also very suitable to be used for fencing since they provide 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.
    As used herein, the term "passivated metal wire" refers to a metal wire comprising a metal core surrounded by an inner zinc coating layer, surrounded by a layer of a passivation coating comprising trivalent chromium and cobalt. The thickness of the passivation 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 another step of the method according to the present invention, the passivated metal wire is transported or guided in a continuous manner through a sealing solution comprising a synthetic polymer and a non-ionic surfactant, thereby providing a sealing coating on said passivated metal wire is applied and the coated metal wire according to the present invention is obtained. According to the method of the present invention, this process step is referred to as a sealing step in which a coating layer is applied to the passivated metal wire. This sealing step can take place with the aid of all sealing methods known in the art and preferably by passing the passivated metal wire through a sealing solution.
    The sealing method refers to a method of providing the coated metal wire with an outer coating layer for resisting aggressive environments. The sealing coating gives the coated metal wire a different coating layer for corrosion resistance. This can be explained by the closed structure of the sealing coating and by the intrinsic inert properties of the sealant. In a further embodiment, the present invention refers to a method according to the present invention wherein said sealing solution comprises a synthetic polymer and a non-ionic surfactant.
    In the method of the present invention, the sealing solution comprises a synthetic polymer and a non-ionic surfactant. Preferably, said sealing solution is an aqueous solution. Preferably, the passivation solution according to the present invention is free or substantially free of chromium.
    The sealing coating is preferably applied from an aqueous solution comprising a synthetic polymer and a non-ionic surfactant. The synthetic polymer is preferably a polyethylene polymer such as, but not limited to, polystyrene, polyvinyl chloride (PVC), polyethylene covinyl acetate, polyacrylic acid and styrene. The sealing coating of the present invention may also comprise a copolymer based on an olefin, acrylic acid, butyl, acrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, acrylonitrile, methyl methacrylate and / or TMPTA. In a preferred embodiment, the aqueous solution comprises a copolymer of ethylene and acrylic acid. Alternatively, other copolymers such as a copolymer of styrene and acrylic acid can be used. It is important to note that the aqueous solution comprising the copolymer based on an olefin and acrylic acid is chromium-free or substantially chromium-free.
    The non-ionic surfactant refers to a humidifier that reduces the surface tension of a solution, which allows easier distribution, and which reduces the surface tension between two solutions. Non-limiting examples of non-ionic surfactants include alkyl poly (ethylene oxide), polyalkyl phenol (ethylene oxide), copolymers of poly (ethylene oxide) and poly (propylene oxide), alkyl polyglucosides including octy-Iglucoside and decyl maloside, fatty acid alcohols including cetyl alcohol and oleyl alcohol, cocamide MEA, cocamide DEA, polysorbates such as Tween 20 and Tween 80, dodecyl dimethylamine oxide, isotridecanol ethoxylate and / or benzisothiazolidinone. More preferably, said sealing solution is SurTec 558 black ™.
    In a specific embodiment, the present invention provides a method according to the present invention wherein the residence time of said passivated metal wire with 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 another specific embodiment, the present invention refers to a method according to the present invention in which the metal core wire is transported from a starting position where a roll of said metal core wire is unwound, along a predetermined route through various treatment baths which contain 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 processing steps of the present invention, an in-line method is generated that provides a fast and inexpensive method of coating a metal wire.
    In the method according to the present invention, additional process steps of the metal wire can be included such as degreasing, rinsing, biting, wire drawing and / or drying. The method according to the present invention results in a simplified method. Applying the coating according to the present invention can be carried out in a continuous, in-line method 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 rinsing can be performed before and after the galvanizing method, and after the passivation method. 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 placed in 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, hydrogen bromide 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 method for manufacturing a coated metal wire according to the present invention comprises the further steps of: (1) unwinding a wire with metal core from a roll; (2) degreasing said metal core wire; (3) spooling said metal core wire; (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.
    The present invention also relates to 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, said radial inner layer layer is a zinc layer, said radial central layer is a passivation layer comprising trivalent chromium and cobalt and said radial outer layer is a sealing layer comprising a synthetic polymer.
    In a further embodiment, the present invention relates to a 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 25 µm and more preferably between 2 µm and 15 µm, wherein the thickness of said radial central layer is between 50 and 750 nm, preferably between 100 nm and 600 nm, more preferably between 150 nm and 50 nm and more preferably between approximately 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 further embodiment, the present invention relates to a coated metal wire according to the present invention, wherein said radial inner layer substantially comprises zinc and / or wherein said radial central layer has a chromium content, and preferably a trivalent chromium content that lies between 93.00% and 99.96% and a cobalt content that is between 0.04% and 7.00%.
    In another embodiment, the present invention relates to a coated metal wire according to the present invention, wherein said radial center layer is free or substantially free of hexavalent chromium.
    In a further embodiment, the present invention relates to a 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 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, control rods and other metal wire products such as screens, racks, nets, lampshades, frames, hooks, brackets, clips, rings and springs.
    The 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 capacity 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 of the prior art often show that by applying a coating to the metal wire the weldability diminishes. 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 coating layers, allowing the coated wires to have a specific color, and this without affecting the other characteristics of the coated metal wire.
    The present invention also relates to the use of one or more 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.
    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) in a continuous manner through a passivation solution comprising trivalent chromium ions, cobalt ions and nitrate ions, 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 synthetic polymer and a non-ionic surfactant, 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 galvanized metal wire in said passivation solution according to step (b) is between 15 and 60 seconds and preferably between 25 and 35 seconds and more preferably 30 seconds.
    [3]
    The method of claim 1 or 2, wherein the temperature of said passivation solution is between 40 ° C and 100 ° C and the pH of said passivation solution is between 1.0 and 3.0.
    [4]
    The method according to any of claims 1 to 3, wherein said passivation solution comprises trivalent chromium ions in a concentration that is between 1 g / L and 100 g / L and cobalt ions in a concentration that is between 0.005 g / L and 5 g / L.
    [5]
    The method according to any of claims 1 to 4, wherein said passivation solution comprises dyes.
    [6]
    The method according to any of claims 1 to 5, wherein said sealing solution according to step (c) comprises a synthetic polymer and a non-ionic surfactant.
    [7]
    The method of 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. * V
    [8]
    A coated metal wire 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, said radial inner layer being a zinc layer, said radial center layer is a passivation layer comprising trivalent chromium and cobalt and said radial outer layer is a sealing layer comprising a synthetic polymer.
    [9]
    A 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 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 chromium content that is between 93.00% and 99.96% and a cobalt content that is between 0, 04% and 7.00%.
    [11]
    A coated metal wire according to any of claims 9 to 10, wherein said radial center layer is free from hexavalent chromium.
    [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
    EP2325353A1|2011-05-25|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    GB2144773A|1983-07-19|1985-03-13|Omi Int Corp|Non-peroxide trivalent chromium passivation|
    EP1484432A1|2002-03-14|2004-12-08|Dipsol Chemicals Co., Ltd.|Treating solution for forming black hexavalent chromium-free chemical coating on zinc or zinc alloy plated substrate, and method for forming black hexavalent chromium-free chemical coating on zinc or zinc alloy plated substrate|
    KR100790269B1|2006-12-21|2008-01-02|한국선재|Method of making wire and steel wire|
    法律状态:
    2018-02-15| MM| Lapsed because of non-payment of the annual fee|Effective date: 20170131 |
    优先权:
    申请号 | 申请日 | 专利标题
    EP09174452|2009-10-29|
    EP09174452|2009-10-29|
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