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WO2016115367A1 - Systèmes et procédés de fourniture de composites mis en forme qui comprennent des films de polymère fluoré - Google Patents

Systèmes et procédés de fourniture de composites mis en forme qui comprennent des films de polymère fluoré Download PDF

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Publication number
WO2016115367A1
WO2016115367A1 PCT/US2016/013436 US2016013436W WO2016115367A1 WO 2016115367 A1 WO2016115367 A1 WO 2016115367A1 US 2016013436 W US2016013436 W US 2016013436W WO 2016115367 A1 WO2016115367 A1 WO 2016115367A1
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WO
WIPO (PCT)
Prior art keywords
film
ptfe
metal
composite
metal structure
Prior art date
Application number
PCT/US2016/013436
Other languages
English (en)
Inventor
John TIPPETT
Original Assignee
Textiles Coated Incorporated
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Filing date
Publication date
Application filed by Textiles Coated Incorporated filed Critical Textiles Coated Incorporated
Publication of WO2016115367A1 publication Critical patent/WO2016115367A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B29C69/001—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/085—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B32B27/322—Layered products comprising a layer of synthetic resin comprising polyolefins comprising halogenated polyolefins, e.g. PTFE
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2202/00—Metallic substrate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2701/00—Coatings being able to withstand changes in the shape of the substrate or to withstand welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/08—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain an anti-friction or anti-adhesive surface
    • B05D5/083—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain an anti-friction or anti-adhesive surface involving the use of fluoropolymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/12—Use of polyvinylhalogenides or derivatives thereof as moulding material containing fluorine
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/12—Use of polyvinylhalogenides or derivatives thereof as moulding material containing fluorine
    • B29K2027/18—PTFE, i.e. polytetrafluorethene, e.g. ePTFE, i.e. expanded polytetrafluorethene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2305/00—Use of metals, their alloys or their compounds, as reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/514—Oriented
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/514—Oriented
    • B32B2307/516—Oriented mono-axially
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/542—Shear strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2327/00—Polyvinylhalogenides
    • B32B2327/12—Polyvinylhalogenides containing fluorine
    • B32B2327/18—PTFE, i.e. polytetrafluoroethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0007—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
    • B32B37/003—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality to avoid air inclusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details

Definitions

  • This present invention generally relates to the forming of a composite that includes a metal structure and a fluoropolymer film on at least a portion of the metal structure.
  • Fluoroplastic materials give excellent chemical protection, release properties, and lubrication to metal surfaces.
  • a common product found in many households is a metal frying pan with a non-stick fluoroplastic surface.
  • Thin PTFE spray coatings are inherently weak and brittle. Over time, these coatings may develop poor adhesion to metal and may become susceptible to removal upon slight agitation. For example, many households have experienced common failure of PTFE coatings on metal frying pans when using metal spatulas with sharp metal edges. The metal edges of a spatula may apply forces during use that result in the removal of the PTFE coating on a metal frying pan, ruining the non-stick properties of the frying pan to food.
  • Thin PTFE coatings may also have permeation concerns.
  • a PTFE coating is inherently permeable. Liquids may permeate into PTFE surfaces over time and repeated use. As a PTFE surface is permeated by a foreign material, long-term release properties may be diminished. For example, the non-stick surface of a frying pan will eventually fail to release after long-term exposure to cooking. Oils from food permeate into the surface of the thin PTFE coating on metal, compromising its release properties. Food cooked on such a compromised surface may be permeated with oils and residue from previous cooking sessions. Thus, the non-stick properties are therefore, inferior to when the frying pan was first used without the permeants in the coating surface.
  • the bond between the PTFE coating and metal may be diminished from permeation.
  • a build-up of permeants can form between metal and the PTFE coating. This build-up may cause delamination or flaking-off of the PTFE coating from the metal.
  • the invention provides a method of forming a shaped composite that includes the steps of: providing a metal structure; bonding at a bond interface, a fluoroplolymeric film to the metal structure to form a composite structure, said bond interface including in at least some areas, a mingling of molecules of the fluoropolymeric film with molecules of the metal structure; and shaping the composite structure to form the non-flat shaped composite, the step of shaping involving maintaining a substantial amount of the areas of mingled molecules of the fluoropolymeric film and the molecules of the metal structure.
  • Figure 1 shows an illustrative diagrammatic view of the formation of a fluoroplastic film for use in an embodiment of the invention that includes a laminate of cross-oriented fluoroplastic layers;
  • Figure 2 shows an illustrative diagrammatic view of the laminated fluoroplastic film of Figure 1;
  • Figure 3 shows an illustrative diagrammatic view the formation of a cast fluoroplastic film for use in accordance with an embodiment of the present invention
  • Figure 4 shows an illustrative diagrammatic view of the cast fluoroplastic film of Figure 3;
  • Figure 6 shows an illustrative diagrammatic view of the skived fluoroplastic film of Figure 5;
  • Figures 7 A and 7B shows an illustrative diagrammatic views of the bonding of the laminated fluoroplastic film of Figures 1 and 2 to a metal structure;
  • Figures 9A and 9B shows an illustrative diagrammatic views of the bonding of the skived fluoroplastic film of Figures 5 and 6 to a metal structure;
  • Figure 11 shows an illustrative diagrammatic view of the composite of Figure 10 during the application of heat and pressure
  • Figure 12 shows an illustrative diagrammatic view of a portion of the composite structure of Figure 10;
  • Figure 13 shows an illustrative diagrammatic view of a portion of the shaped composite of Figure 11;
  • Figure 14 shows an illustrative diagrammatic view of a curved portion of the shaped composite of Figure 11;
  • Figure 15 shows an illustrative diagrammatic view of a portion of a shaped composite in accordance with an embodiment of the invention undergoing an externally applied force.
  • the invention incorporates a barrier PTFE film surface that has been bonded to a flat metal surface.
  • the metal component may be prepared in advance for bonding.
  • a separate high-temperature adhesive material may be used to facilitate the bond between the prepared metal and fluoroplastic (e.g., PTFE) film surface.
  • the barrier PTFE film surface may be made prior to bonding to metal or during the bonding to metal process. In the bonding to metal process, high temperature and pressure are used to melt the high-temperature adhesive and enact a bond between the barrier PTFE film and the prepared metal.
  • metal surface may be considered a candidate for composites of the invention.
  • the sole limitation in metal is that it must be able to withstand the high-temperature bonding process used to make the laminate. Typical bonding temperatures will range from 400°F to 900°F.
  • One or both of the metal surfaces are prepared for bonding using typical industry methods such as sanding, sand blasting, grinding, and chemical treatment.
  • chemical primers may be coated to the metal for further bonding improvement to PTFE.
  • a high-temperature adhesive layer may be provided in between the metal and PTFE surfaces.
  • the adhesive layer may consist of a perfluoroalkoxy (PFA) film or coating, fluorinated ethylene propylene (FEP) film or coating, or PTFE film or coating. Blends of the three materials in film or coating form may also be used as an adhesive layer. Typical film thicknesses may range from a 1/4 mil to 200 mils. Liquid coatings of PTFE, PFA, or FEP dispersion may be sintered or unsintered.
  • Candidate barrier PTFE films made from fine powders include extruded PTFE films, PTFE Crossfilms (as disclosed, for example in U.S. Patent No. 5,466,531, the disclosure of which is hereby incorporated by reference in its entirety), cast PTFE films, expanded PTFE films, and modified PTFE films.
  • a laminated fluoroplastic film 10 for use in a composite of the invention may include a plurality of axially oriented PTFE films 12, 14, 16 laminated directly together, i.e., without the interposition of an adhesive or bonding agent therebetween.
  • the PTFE films are preferably unsintered prior to lamination, and preferably are uniaxially oriented, with at least one of the films having its direction of orientation disposed angularly with respect to that of at least one other of the films.
  • An example of a layout of film orientations is shown in FIG. 1.
  • PTFE film thicknesses will typically range between 1-10 mils, and preferably from 2-5 mils.
  • the unsintered PTFE films may be prepared by a process that involves mixing powdered PTFE resin with a solvent to produce a paste, and the paste is preformed to remove air, extruded into a film, and then calendared to a desired thickness. The calendared film is then dried to evaporate the solvent. The films are then oriented and laminated in accordance with the embodiment of FIGs. 1 and 2.
  • Lamination is effected between heated platens under conditions of elevated pressure and temperature for varying time intervals.
  • Lamination pressures need only be sufficient to expel entrapped air from between the plies while promoting intimate face-to-face contact. Pressures at or above 1 p.s.i. have been deemed adequate, with the preferred pressure range being between about 40-60 p.s.i.
  • Lamination temperatures are selected to accommodate numerous variables, including differing laminator designs and thermal capabilities, the type of PTFE film being processed, e.g., sintered or unsintered, the number and thickness of the films making up the laminate, the residence time of the films in the laminator, etc.
  • Lamination times are selected to achieve uniform cross sectional heating of the laminate, and are otherwise minimized in order to promote production efficiencies.
  • Typical lamination times range between 20-70 seconds, depending on the other process and equipment variables described above. Thicknesses of these films (prior to bonding to a metal substrate as discussed below) range from 1/4 mil to 200 mils.
  • a skived fluoroplastic film 30 may be used to form a composite of the invention.
  • the fluoroplastic (e.g., PTFE) material may be skived from a block 32 using a blade 34.
  • the skived PTFE film is produced in a sintered form. In order to laminate the film, the film is heated to about 650 °F.
  • Candidate PTFE films made from liquid dispersion include cast PTFE films. These films have a thickness range of 1/4 mil to 200 mils prior to bonding. A typical maximum single layer of cast PTFE film is around 6 mils. Single layers of cast PTFE film may be stacked to achieve thicknesses far greater than 6 mils. The films were sintered during lamination, and retained their respective directions of orientation following lamination.
  • the laminated fluoroplastic film (10) may be bonded to a metal substrate 40 either directly or using an intermediate PFA or FEP film (as shown in FIG. 7B) to form a composite structure.
  • the PTFE film includes the intermediate layer of PFA.
  • the cast fluoroplastic film (20) may be bonded to a metal substrate 40 either directly or using an intermediate PFA or FEP film (as shown in FIG. 8B) to form a composite structure.
  • the PTFE film includes the intermediate layer of PFA. As shown in FIGs.
  • the cast fluoroplastic film (20) may be bonded to a metal substrate 40 either directly or using an intermediate PFA or FEP film (as shown in FIG. 9B) to form a composite structure.
  • the PTFE film includes the intermediate layer of PFA.
  • the barrier PTFE film surface may be prepared for adhesion to metal using various forms of etching processes typically used for bonding PTFE to dissimilar materials. These processes include corona etching, sodium naphthalene etching, and sodium ammonium etching, to name three processes
  • Temperature and pressure are required to achieve an effective bond between PTFE and metal surfaces. As discussed above, the typical bonding temperature will range from 400°F to 900°F. The temperature must be sufficient to activate the beneficial properties of the separate adhesive layer. Pressure will be delivered using any piece of equipment with flat surfaces that will force a high bond between the PTFE film and flat sheet of metal.
  • the flat-sheet PTFE/metal laminate (composite structure) is capable of surviving conventional metal forming techniques without comprising the integrity of the PTFE film surface.
  • the fluoroplastic film 58 e.g., laminated, cast or skived
  • the desired attributes of the composite structure 52 associated with a PTFE surface are unchanged and intact in the composite structure of 52' after the arduous metal-forming processes.
  • This invention relates to metal forming processes that are related to the stretching of metal. These processes include deep drawing, stretch forming, hydro forming, and bladder forming.
  • lubricants such as silicone oil or PTFE spray coating may be used as a mold aid to reduce the exposure to significant shearing forces.
  • the lubricant may be applied to all contacted PTFE surfaces in the forming processes. Since a PTFE surface is self-lubricating, the spray coating may or may not be needed as a molding aid.
  • the typical bond strength between a barrier PTFE film and metal in a flat-sheet laminate ranges from 1 lbs/in of width to 200 lbs/in of width.
  • Adhesion value decrease may range from 1% to 50%. This measurement is deemed inconsequential because a proper initial design of required adhesion levels in the flat-sheet laminate can offset decreases that may occur during the metal reshaping process.
  • the increased thickness, toughness, tensile strength, and tear resistance properties of the barrier PTFE films on the surface of metal significantly improves the abrasion-resistance of the PTFE/metal laminate. These improved physical properties can act independently or cumulatively to assist the adhesion between the PTFE and metal surfaces. Because a thin and brittle PTFE coating does not have significant toughness, tensile strength, and tear-resistance properties, it is not able to contribute in strength properties to the adhesion between PTFE and metal surfaces. The thin and brittle PTFE coating is easily removed with surface agitation or metal deformation.
  • Thick and capable barrier PTFE film surfaces also may have elongation properties that contribute to the integrity of the PTFE surface. If a thick and capable PTFE film surface is contacted by the sharp edge of a metal spatula, a capable PTFE film may have the elongation capability to resist tearing, delamination, or flaking. A thin and brittle PTFE coating is more likely to delaminate or flake off rather than elongate when agitated.
  • an aesthetically-pleasing PTFE surface is achieved after the metal forming process.
  • a quality PTFE appearance is maintained during a reshaping or forming process without heat. It is generally expected that a PTFE surface will undergo an appearance transition during the reshaping process to a heavily whitened and/or stressed condition. The whitened/and or stressed condition may preclude the use of the three-dimensional product in commercial applications where aesthetics are important. Contrary from the expected, it is found that the compressive forces during the metal reshaping process eliminate the presence of stressed or whitened PTFE surfaces.
  • the bond interface between the metal film 40 and the fluorolastic film 58 (laminated, cast or skived, and with or without the intermediate PFA or FEP layer) in the composite structure may be characterized has having a peel strength at the location shown at 60 of at least about 1 lb / inch of width as tested in accordance with ASTM D.1876.
  • the peel strength at the bond interface of the composite structure may be at least 5 lb / inch of width, and in certain embodiments, it may be at least 10 lb / inch of width. All peel strength testing herein may be provided in accordance with ASTM D.1876.
  • the bond interface shown at 62 between the metal film 40 and the fluoroplastic film 58 (laminated, cast or skived, and with or without the intermediate PFA or FEP layer) in the shaped composite 52' may be characterized has having a peel strength of at least about 1 lb / inch of width as tested in accordance with ASTM D.1876.
  • the peel strength at the bond interface of the shaped composite may be at least 5 lb / inch of width, and in certain embodiments, it may be at least 10 lb / inch of width.
  • the bond interface 64 of the shaped composite 52' includes areas of mingling of the metal and polymeric materials such that regardless of whether the metal structure is in compression or tension when shaped, the polymeric material remains firmly attached to the molecules of the metal structure.
  • A when the shaped composite is bent, the outer layer will be stretched due to tension if the material is able to stretch, while the inner material in the bend will be compressed as shown at B.
  • the PTFE film may be able to change shape to some extent, the metal substrate would not be able to undergo the same amount of change (and may not change its length at all).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un composite mis en forme qui comprend une structure métallique qui a été formée de manière à présenter une forme non plate, ledit composite mis en forme comprenant un film de polymère fluoré lié à une surface de la structure métallique de sorte qu'une résistance au pelage entre la structure métallique et le film de polymère fluoré soit d'au moins environ 1 livre/pouce de largeur.
PCT/US2016/013436 2015-01-14 2016-01-14 Systèmes et procédés de fourniture de composites mis en forme qui comprennent des films de polymère fluoré WO2016115367A1 (fr)

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US62/103,324 2015-01-14

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6039755A (en) * 1997-02-05 2000-03-21 Impra, Inc., A Division Of C.R. Bard, Inc. Radially expandable tubular polytetrafluoroethylene grafts and method of making same
US20020031628A1 (en) * 1998-02-13 2002-03-14 Michael Allen Zumbrum Flexure endurant composite elastomer compositions
US20040058112A1 (en) * 2002-09-25 2004-03-25 Ats Products, Inc. Method for making tubular articles
US20120251021A1 (en) * 2011-04-04 2012-10-04 Swei Gwo S Self-lubricating structure and method of manufacturing same
US20130065059A1 (en) * 2011-03-07 2013-03-14 E. I. Du Pont De Nemours And Company Method of adhering ionomer to metal

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6039755A (en) * 1997-02-05 2000-03-21 Impra, Inc., A Division Of C.R. Bard, Inc. Radially expandable tubular polytetrafluoroethylene grafts and method of making same
US20020031628A1 (en) * 1998-02-13 2002-03-14 Michael Allen Zumbrum Flexure endurant composite elastomer compositions
US20040058112A1 (en) * 2002-09-25 2004-03-25 Ats Products, Inc. Method for making tubular articles
US20130065059A1 (en) * 2011-03-07 2013-03-14 E. I. Du Pont De Nemours And Company Method of adhering ionomer to metal
US20120251021A1 (en) * 2011-04-04 2012-10-04 Swei Gwo S Self-lubricating structure and method of manufacturing same

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