US6276400B1
Expired / Lapsed
US
⏱️ 0.0 years remaining
Corrosion resistant powder coated metal tube and process for making the same
Assignee: ITT Manufacturing Enterprises LLC
•
Filing: 1999-06-08
•
Granted: 2001-08-21
•
Expires: 2019-06-08
Abstract
Abstract A corrosion resistant tube comprises a metal tube having an outer surface. A zinc layer is electrostatically bonded to the outer surface, wherein the zinc layer is selected from the group consisting of powdered zinc, powdered zinc nickel alloys, powdered zinc cobalt alloys, and powdered zinc aluminum alloys. Optionally, one or more polymeric layers may be electrostatically bonded to the zinc layer, or to a surface treatment layer, wherein the polymeric layer(s) comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof. Optionally, the polymeric layer(s) may be electrostatically bonded directly to the outer surface. A process for producing corrosion resistant tubing comprises the steps of: electrostatically charging aerated particles of a powdered material in a fluidizing chamber; conveying grounded metal tubing through the charged particles, thereby uniformly coating the tubing outer surface; and heating the coated tubing.
Inventors
- 👤 Timothy E. Jackson
- 👤 Tao Nie
- 👤 Steve Obbish
- 👤 II John F. Schloemp
- 👤 Robert Church
- 👤 Michael W. Boles
- 👤 Gary O. Klinger
- 👤 Christopher R. Terry
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 14:29
CPC Classifications
B; B05; B05D; B05D7/00; B05D7/50; B05D7/52; B05D7/54; B05C; B05C19/00; B05C19/02; B05C19/025; B05D3/00; B05D3/02; B05D3/0209; B05D7/14; B05D7/146; B05D7/56; B05D7/58; C; C23; C23C; C23C24/00; F; F16; F16L; F16L58/00; F16L58/02; F16L58/04; B05D1/00; B05D1/02; B05D1/04; B05D1/06; B05D3/0254; B05D3/0263; B05D3/0272
Claims Analysis
Total Claims: 68
Claim 1
Independent Claim
71 words
A corrosion resistant tube, comprising: a metal tube having an outer surface; and a zinc layer electrostatically bonded to the metal tube outer surface, wherein the zinc layer is selected from the group consisting of powdered zinc; powdered zinc alloys consisting essentially of zinc and a polymeric matrix, or zinc and an epoxy matrix; powdered zinc powdered zinc nickel alloys; powdered zinc cobalt alloys; powdered zinc aluminum alloys; and mixtures thereof.
Claim 2
Dependent Claim
71 words
A corrosion resistant tube, comprising: a metal tube having an outer surface; and a zinc layer electrostatically bonded to the metal tube outer surface, wherein the zinc layer is selected from the group consisting of powdered zinc; powdered zinc alloys consisting essentially of zinc and a polymeric matrix, or zinc and an epoxy matrix; powdered zinc powdered zinc nickel alloys; powdered zinc cobalt alloys; powdered zinc aluminum alloys; and mixtures thereof.
Claim 3
Dependent Claim
25 words
The corrosion resistant tube as defined in claim 1 wherein the zinc layer has a thickness ranging between about 10 microns and about 75 microns.
Claim 4
Dependent Claim
19 words
The corrosion resistant tube as defined in claim 1 wherein the zinc layer is a zinc epoxy powder coating.
Claim 5
Dependent Claim
44 words
The corrosion resistant tube as defined in claim 3 wherein the zinc epoxy powder coating has a specific gravity (calculated) of 2.94, and a particle size (Alpine Jet Sieve) using test method ASTM D3451 (% retained) of: +200 Mesh: 0-5%; and +325 Mesh: 5-30%.
Claim 6
Dependent Claim
34 words
The corrosion resistant tube as defined in claim 3 wherein the zinc epoxy powder coating has a salt spray resistance (vertical scribe) using test method ASTM B 117 of greater than about 4000 hours.
Claim 7
Dependent Claim
105 words
A corrosion resistant tube, comprising: a metal tube having an outer surface; and zinc layer electrostatically bonded to the metal tube outer surface, wherein the zinc layer has a thickness ranging between about 10 microns and about 75 microns, and wherein the zinc layer is a zinc epoxy powder coating having a specific gravity (calculated) of 2.94, and a particle size (Alpine Jet Sieve) using test method ASTM D3451 (% retained) of: +200 Mesh: 0-5%; and +325 Mesh: 5-30%, and wherein the zinc epoxy powder coating has a salt spray resistance (vertical scribe) using test method ASTM B 117 of greater than about 4000 hours.
Claim 8
Dependent Claim
105 words
A corrosion resistant tube, comprising: a metal tube having an outer surface; and zinc layer electrostatically bonded to the metal tube outer surface, wherein the zinc layer has a thickness ranging between about 10 microns and about 75 microns, and wherein the zinc layer is a zinc epoxy powder coating having a specific gravity (calculated) of 2.94, and a particle size (Alpine Jet Sieve) using test method ASTM D3451 (% retained) of: +200 Mesh: 0-5%; and +325 Mesh: 5-30%, and wherein the zinc epoxy powder coating has a salt spray resistance (vertical scribe) using test method ASTM B 117 of greater than about 4000 hours.
Claim 9
Dependent Claim
44 words
The corrosion resistant tube as defined in claim 1 , further comprising a polymeric layer electrostatically bonded to the zinc layer, wherein the polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof.
Claim 10
Dependent Claim
25 words
The corrosion resistant tube as defined in claim 7 wherein the polymeric layer has a thickness ranging between about 20 microns and about 200 microns.
Claim 11
Dependent Claim
46 words
The corrosion resistant tube as defined in claim 7 , further comprising a second polymeric layer electrostatically bonded to the polymeric layer, wherein the second polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof.
Claim 12
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 9 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 20 microns and about 200 microns.
Claim 13
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 9 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 50 microns and about 100 microns.
Claim 14
Dependent Claim
26 words
The corrosion resistant tube as defined in claim 9 wherein the polymeric layer and the second polymeric layer, combined, have a thickness of about 75 microns.
Claim 15
Dependent Claim
19 words
The corrosion resistant tube as defined in claim 9 wherein the polymeric layer consists essentially of powdered polyvinylidene fluoride.
Claim 16
Dependent Claim
28 words
The corrosion resistant tube as defined in claim 13 wherein the powdered polyvinylidene fluoride has an average particle size of between about 20 μm and about 30 μm.
Claim 17
Dependent Claim
20 words
The corrosion resistant tube as defined in claim 13 wherein the second polymeric layer consists essentially of powdered Nylon 12.
Claim 18
Dependent Claim
28 words
The corrosion resistant tube as defined in claim 15 wherein the powdered Nylon 12 has an average particle size of between about 20 μm and about 30 μm.
Claim 19
Dependent Claim
172 words
A corrosion resistant tube, comprising: a metal tube having an outer surface; a zinc layer electrostatically bonded to the metal tube outer surface, wherein the zinc layer has a thickness ranging between about 10 microns and about 75 microns, and wherein the zinc layer is a zinc epoxy powder coating having a specific gravity (calculated) of 2.94, and a particle size (Alpine Jet Sieve) using test method ASTM D3451 (% retained) of: +200 Mesh: 0-5%; and +325 Mesh: 5-30%, and wherein the zinc epoxy powder coating has a salt spray resistance (vertical scribe) using test method ASTM B 117 of greater than about 4000 hours; a polymeric layer electrostatically bonded to the zinc layer, wherein the polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof; and a second polymeric layer electrostatically bonded to the polymeric layer, wherein the second polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof.
Claim 20
Dependent Claim
172 words
A corrosion resistant tube, comprising: a metal tube having an outer surface; a zinc layer electrostatically bonded to the metal tube outer surface, wherein the zinc layer has a thickness ranging between about 10 microns and about 75 microns, and wherein the zinc layer is a zinc epoxy powder coating having a specific gravity (calculated) of 2.94, and a particle size (Alpine Jet Sieve) using test method ASTM D3451 (% retained) of: +200 Mesh: 0-5%; and +325 Mesh: 5-30%, and wherein the zinc epoxy powder coating has a salt spray resistance (vertical scribe) using test method ASTM B 117 of greater than about 4000 hours; a polymeric layer electrostatically bonded to the zinc layer, wherein the polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof; and a second polymeric layer electrostatically bonded to the polymeric layer, wherein the second polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof.
Claim 21
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 17 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 75 microns and about 300 microns.
Claim 22
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 17 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 50 microns and about 80 microns.
Claim 23
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 17 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 150 microns and about 200 microns.
Claim 24
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 17 wherein the polymeric layer consists essentially of powdered polyvinylidene fluoride, and wherein the second polymeric layer consists essentially of powdered Nylon 12.
Claim 25
Dependent Claim
48 words
The corrosion resistant tube as defined in claim 21 wherein the powdered polyvinylidene fluoride has an average particle size of between about 20 μm and about 30 μm, and wherein the powdered Nylon 12 has an average particle size of between about 20 μm and about 30 μm.
Claim 26
Dependent Claim
111 words
A corrosion resistant tube, comprising: a metal tube having an outer surface; a zinc layer bonded to the metal tube outer surface, wherein the zinc layer is selected from the group consisting of zinc plating, zinc nickel alloys, zinc cobalt alloys, zinc aluminum alloys, and mixtures thereof; a surface treatment layer bonded to the zinc layer, wherein the surface treatment layer is selected from the group consisting of a zinc/aluminum/rare earth alloy, phosphate, chromate, and mixtures thereof; and a polymeric layer electrostatically bonded to the surface treatment layer, wherein the polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof.
Claim 27
Dependent Claim
111 words
A corrosion resistant tube, comprising: a metal tube having an outer surface; a zinc layer bonded to the metal tube outer surface, wherein the zinc layer is selected from the group consisting of zinc plating, zinc nickel alloys, zinc cobalt alloys, zinc aluminum alloys, and mixtures thereof; a surface treatment layer bonded to the zinc layer, wherein the surface treatment layer is selected from the group consisting of a zinc/aluminum/rare earth alloy, phosphate, chromate, and mixtures thereof; and a polymeric layer electrostatically bonded to the surface treatment layer, wherein the polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof.
Claim 28
Dependent Claim
25 words
The corrosion resistant tube as defined in claim 23 wherein the polymeric layer has a thickness ranging between about 20 microns and about 200 microns.
Claim 29
Dependent Claim
46 words
The corrosion resistant tube as defined in claim 23 , further comprising a second polymeric layer electrostatically bonded to the polymeric layer, wherein the second polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof.
Claim 30
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 25 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 50 microns and about 300 microns.
Claim 31
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 25 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 50 microns and about 100 microns.
Claim 32
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 25 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 150 microns and about 200 microns.
Claim 33
Dependent Claim
19 words
The corrosion resistant tube as defined in claim 25 wherein the polymeric layer consists essentially of powdered polyvinylidene fluoride.
Claim 34
Dependent Claim
28 words
The corrosion resistant tube as defined in claim 29 wherein the powdered polyvinylidene fluoride has an average particle size of between about 20 μm and about 30 μm.
Claim 35
Dependent Claim
20 words
The corrosion resistant tube as defined in claim 25 wherein the second polymeric layer consists essentially of powdered Nylon 12.
Claim 36
Dependent Claim
28 words
The corrosion resistant tube as defined in claim 31 wherein the powdered Nylon 12 has an average particle size of between about 20 μm and about 30 μm.
Claim 37
Dependent Claim
139 words
A corrosion resistant tube, comprising: a metal tube having an outer surface; a zinc layer bonded to the metal tube outer surface, wherein the zinc layer is selected from the group consisting of zinc plating, zinc nickel alloys, zinc cobalt alloys, zinc aluminum alloys, and mixtures thereof; a surface treatment layer bonded to the zinc layer, wherein the surface treatment layer is selected from the group consisting of a zinc/aluminum/rare earth alloy, phosphate, chromate, and mixtures thereof; a polymeric layer electrostatically bonded to the surface treatment layer, wherein the polymeric layer is selected from the group consisting of powdered polyvinylidene fluoride, powdered Nylon 12, and mixtures thereof; and a second polymeric layer electrostatically bonded to the polymeric layer, wherein the second polymeric layer is selected from the group consisting of powdered polyvinylidene fluoride, powdered Nylon 12, and mixtures thereof.
Claim 38
Dependent Claim
139 words
A corrosion resistant tube, comprising: a metal tube having an outer surface; a zinc layer bonded to the metal tube outer surface, wherein the zinc layer is selected from the group consisting of zinc plating, zinc nickel alloys, zinc cobalt alloys, zinc aluminum alloys, and mixtures thereof; a surface treatment layer bonded to the zinc layer, wherein the surface treatment layer is selected from the group consisting of a zinc/aluminum/rare earth alloy, phosphate, chromate, and mixtures thereof; a polymeric layer electrostatically bonded to the surface treatment layer, wherein the polymeric layer is selected from the group consisting of powdered polyvinylidene fluoride, powdered Nylon 12, and mixtures thereof; and a second polymeric layer electrostatically bonded to the polymeric layer, wherein the second polymeric layer is selected from the group consisting of powdered polyvinylidene fluoride, powdered Nylon 12, and mixtures thereof.
Claim 39
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 33 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 75 microns and about 300 microns.
Claim 40
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 33 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 50 microns and about 80 microns.
Claim 41
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 33 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 150 microns and about 200 microns.
Claim 42
Dependent Claim
19 words
The corrosion resistant tube as defined in claim 33 wherein the polymeric layer consists essentially of powdered polyvinylidene fluoride.
Claim 43
Dependent Claim
28 words
The corrosion resistant tube as defined in claim 37 wherein the powdered polyvinylidene fluoride has an average particle size of between about 20 μm and about 30 μm.
Claim 44
Dependent Claim
20 words
The corrosion resistant tube as defined in claim 33 wherein the second polymeric layer consists essentially of powdered Nylon 12.
Claim 45
Dependent Claim
28 words
The corrosion resistant tube as defined in claim 39 wherein the powdered Nylon 12 has an average particle size of between about 20 μm and about 30 μm.
Claim 46
Dependent Claim
56 words
A corrosion resistant metal tube having a metallic corrosion resistant composition applied to an outer surface thereof, the corrosion resistant tube comprising: a polymeric layer electrostatically bonded to the metallic corrosion resistant composition, wherein the polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof.
Claim 47
Dependent Claim
56 words
A corrosion resistant metal tube having a metallic corrosion resistant composition applied to an outer surface thereof, the corrosion resistant tube comprising: a polymeric layer electrostatically bonded to the metallic corrosion resistant composition, wherein the polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof.
Claim 48
Dependent Claim
25 words
The corrosion resistant tube as defined in claim 41 wherein the polymeric layer has a thickness ranging between about 20 microns and about 200 microns.
Claim 49
Dependent Claim
46 words
The corrosion resistant tube as defined in claim 41 , further comprising a second polymeric layer electrostatically bonded to the polymeric layer, wherein the second polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof.
Claim 50
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 43 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 75 microns and about 300 microns.
Claim 51
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 43 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 50 microns and about 80 microns.
Claim 52
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 43 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 150 microns and about 200 microns.
Claim 53
Dependent Claim
19 words
The corrosion resistant tube as defined in claim 43 wherein the polymeric layer consists essentially of powdered polyvinylidene fluoride.
Claim 54
Dependent Claim
28 words
The corrosion resistant tube as defined in claim 47 wherein the powdered polyvinylidene fluoride has an average particle size of between about 20 μm and about 30 μm.
Claim 55
Dependent Claim
20 words
The corrosion resistant tube as defined in claim 43 wherein the second polymeric layer consists essentially of powdered Nylon 12.
Claim 56
Dependent Claim
28 words
The corrosion resistant tube as defined in claim 49 wherein the powdered Nylon 12 has an average particle size of between about 20 μm and about 30 μm.
Claim 57
Dependent Claim
85 words
A corrosion resistant metal tube having a metallic corrosion resistant composition applied to an outer surface thereof, the corrosion resistant tube comprising: a polymeric layer electrostatically bonded to the metallic corrosion resistant composition, wherein the polymeric layer is selected from the group consisting of powdered polyvinylidene fluoride, powdered Nylon 12, and mixtures thereof; and a second polymeric layer electrostatically bonded to the polymeric layer, wherein the second polymeric layer is selected from the group consisting of powdered polyvinylidene fluoride, powdered Nylon 12, and mixtures thereof.
Claim 58
Dependent Claim
85 words
A corrosion resistant metal tube having a metallic corrosion resistant composition applied to an outer surface thereof, the corrosion resistant tube comprising: a polymeric layer electrostatically bonded to the metallic corrosion resistant composition, wherein the polymeric layer is selected from the group consisting of powdered polyvinylidene fluoride, powdered Nylon 12, and mixtures thereof; and a second polymeric layer electrostatically bonded to the polymeric layer, wherein the second polymeric layer is selected from the group consisting of powdered polyvinylidene fluoride, powdered Nylon 12, and mixtures thereof.
Claim 59
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 51 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 75 microns and about 300 microns.
Claim 60
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 51 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 50 microns and about 80 microns.
Claim 61
Dependent Claim
31 words
The corrosion resistant tube as defined in claim 51 wherein the polymeric layer and the second polymeric layer, combined, have a thickness ranging between about 150 microns and about 200 microns.
Claim 62
Dependent Claim
19 words
The corrosion resistant tube as defined in claim 51 wherein the polymeric layer consists essentially of powdered polyvinylidene fluoride.
Claim 63
Dependent Claim
28 words
The corrosion resistant tube as defined in claim 55 wherein the powdered polyvinylidene fluoride has an average particle size of between about 20 μm and about 30 μm.
Claim 64
Dependent Claim
20 words
The corrosion resistant tube as defined in claim 51 wherein the second polymeric layer consists essentially of powdered Nylon 12.
Claim 65
Dependent Claim
28 words
The corrosion resistant tube as defined in claim 57 wherein the powdered Nylon 12 has an average particle size of between about 20 μm and about 30 μm.
Claim 66
Dependent Claim
81 words
A corrosion resistant tube, comprising: a metal tube having an outer surface; a polymeric layer electrostatically bonded to the metal tube outer surface, wherein the polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof; and a second polymeric layer electrostatically bonded to the polymeric layer, wherein the second polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof.
Claim 67
Dependent Claim
81 words
A corrosion resistant tube, comprising: a metal tube having an outer surface; a polymeric layer electrostatically bonded to the metal tube outer surface, wherein the polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof; and a second polymeric layer electrostatically bonded to the polymeric layer, wherein the second polymeric layer comprises powdered thermoplastic materials selected from the group consisting of powdered nylons, powdered fluoropolymers, powdered polyesters, and mixtures thereof.
Claim 68
Dependent Claim
51 words
The corrosion resistant tube as defined in claim 59 wherein the polymeric layer is selected from the group consisting of powdered polyvinylidene fluoride, powdered Nylon 12, and mixtures thereof, and wherein the second polymeric layer is selected from the group consisting of powdered polyvinylidene fluoride, powdered Nylon 12, and mixtures thereof.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2004-08-20 | 2005-02-19 | 2005-08-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2008-08-20 | 2009-02-19 | 2009-08-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2012-08-20 | 2013-02-19 | 2013-08-21 | $7700.00 | Window Closed / Lapsed |