Methods and apparatus for surface preparation and dual polymeric layer coating of continuous-strip flat-rolled sheet metal, and coated product
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B32B-015/08
B29C-047/02
출원번호
US-0156471
(2002-05-28)
등록번호
US-7452434
(2008-11-18)
발명자
/ 주소
Sinsel,John A.
Loen,Mark V.
Bailey,Michael S.
출원인 / 주소
ISG Technologies, Inc.
대리인 / 주소
Berenato, White & Stavish
인용정보
피인용 횟수 :
0인용 특허 :
10
초록▼
Processes and apparatus for manufacturing an engineered-composite combining rigid flat-rolled sheet metal continuous-strip and selected polypropylene thermoplastics, which are formulated into dual polymeric coating layers for extrusion deposition, as distinct layers, on a single surface at a time, o
Processes and apparatus for manufacturing an engineered-composite combining rigid flat-rolled sheet metal continuous-strip and selected polypropylene thermoplastics, which are formulated into dual polymeric coating layers for extrusion deposition, as distinct layers, on a single surface at a time, of continuous-strip, traveling in-line at ambient temperature. Steps for forming a uniform thickness of polymeric layers across strip width, and attraction to an activated metallic surface which provides enhanced adhesion. Solidification of the polymeric layers is augmented by strip temperature during continuous-in-line travel; final dual-surface finishing provides for complete bonding of the polymeric layers on both metallic surfaces.
대표청구항▼
What is claimed is: 1. A process for extrusion coating a metal strip, comprising the steps of: activating a first metallic surface of a metallic protective coating of a metal strip; presenting the metal strip at substantially ambient temperature and co-extruding a maleic anhydride propylene thermop
What is claimed is: 1. A process for extrusion coating a metal strip, comprising the steps of: activating a first metallic surface of a metallic protective coating of a metal strip; presenting the metal strip at substantially ambient temperature and co-extruding a maleic anhydride propylene thermoplastic polymer first contact layer and a thermoplastic polymer first finish-surface layer onto the activated first metallic surface of substantially ambient temperature and beyond opposite lateral edges of the metal strip to establish overhang portions, the first contact layer being in direct surface-to-surface contact with the activated first metallic surface, the first finish-surface layer overlying the first contact layer; trimming the overhang portions of the first contact layer and the first finish-surface layer extending beyond lateral edges of the metal strip; and permitting the first contact and first finish-surface layers to solidify. 2. The process of claim 1, wherein said permitting step includes allowing the ambient temperature strip to serve as a heat sink so that the first contact layer and the first finish-surface layer solidify on the metal strip. 3. The process of claim 2, wherein the metal strip has a thickness in a range of 5 mils to 15 mils. 4. A process for extrusion coating a metal strip, comprising the steps of: activating a first metallic surface of a metal strip having opposite lateral edges; co-extruding a maleic anhydride polypropylene thermoplastic polymer first contact layer and a thermoplastic polymer first finish-surface layer onto the activated first metallic surface and beyond the opposite lateral edges to establish overhang portions while presenting the metal strip at substantially ambient temperature for said co-extrusion, the first contact layer being co-extruded in direct surface-to-surface contact with the activated first metallic surface, and the first finish-surface layer overlying the first contact layer; trimming the overhang portions of the first contact layer and the first finish-surface layer extending beyond the lateral edges; permitting the first contact and first finish-surface layers to solidify; heating the metal strip and thereby melting the first contact and first finish-surface layers; and rapidly cooling the first contact and first finish-surface layers through glass transition temperatures of the thermoplastic polymers. 5. The process of claim 4, wherein the metal strip is selected from low-carbon steel, aluminum, and aluminum/magnesium alloy. 6. The process of claim 4, further comprising continuously traveling the metal strip in a lengthwise direction during said co-extruding, melting, and rapidly cooling stages. 7. The process of claim 4, wherein said activating step includes exposing the first metallic surface to at least one of open flame treatment, corona-discharge treatment and combinations thereof. 8. The process of claim 4, wherein said substantially ambient temperature is in a range of about 70�� F. to about 90�� F. 9. The process of claim 4, wherein the first finish-surface layer comprises a member selected from the group consisting of ethylene polypropylene copolymer, polypropylene homopolymer, and combinations thereof. 10. The process of claim 4, wherein said melting step causes the first contact layer to fill voids, if any, in the metal strip. 11. The process of claim 4, further comprising the steps of activating a second metallic surface of the metal strip; co-extruding a maleic anhydride polypropylene thermoplastic polymer second contact layer and a thermoplastic polymer second finish-surface layer onto the activated second surface while presenting the metal strip at substantially ambient temperature for said co-extrusion, the second contact layer being co-extruded in direct surface-to-surface contact with the activated second metallic surface, the second finish-surface layer overlying the second contact layer; permitting the second contact and second finish-surface layers to solidify; heating the metal strip and thereby melting the first and second contact layers and the first and second finish-surface layers; and rapidly cooling the first and second contact layers and the first and second finish-surface layers through glass transition temperatures of the thermoplastic polymers. 12. The process of claim 11, wherein the metal strip further comprises first and second non-ferrous metallic protective coatings defining the first and second metallic surfaces, respectively. 13. The process of claim 12, wherein the protective coatings are selected from electrolytic plated tin, electrolytic plated chrome/chrome oxide, cathodic dichromate treatment, electrolytic plated zinc, and hot-dip spelter. 14. The process of claim 11, wherein the first and second finish-surface layers are formed of the same material. 15. The process of claim 11, wherein the first contact and first finish-surface layers are extruded prior to extrusion of the second contact and second finish-surface layers. 16. The process of claim 11, wherein the overhang portions of the first contact layer and first finish-surface layer comprise first overhang portions, and wherein the process further includes the step of extruding the second contact layer and the second finish-surface layer beyond the opposite lateral edges of the strip to establish second overhang portions. 17. The process of claim 16, further including the step of trimming the second overhang portions of the second contact layer and the second finish-surface layer extending beyond the lateral edges. 18. The process of claim 11, including the step of extruding the first and second contact layers and the first and second finish-surface layers at a temperature in excess of the melt temperature of the materials comprising the first and second contact layers and the first and second finish-surface layers. 19. The process of claim 11, wherein said permitting step includes allowing the ambient temperature strip to serve as a heat sink so that the first and second contact layers and the first and second finish-surface layers solidify. 20. The process of claim 11, wherein the heating step is achieved by induction heating of the strip. 21. The process of claim 4, including the step of moving the strip at a speed of about 1500 feet per minute while the activation, co-extrusion, permitting, heating and cooling steps are being performed. 22. The process of claim 4, wherein said permitting step includes allowing the ambient temperature strip to serve as a heat sink so that the first contact layer and the first finish-surface layer solidify on the metal strip. 23. The process of claim 22, wherein the metal strip has a thickness in a range of 5 mils to 15 mils. 24. The process of claim 4, wherein the metal strip further comprises a first non-ferrous metallic protective coating defining the first metallic surface of the metal strip. 25. A process for extrusion coating a metal workpiece, comprising: providing a metal sheet having substantially planar, opposite-facing first and second metallic surfaces extending width-wise between longitudinally extending lateral edges; co-extruding a maleic anhydride polypropylene thermoplastic polymer first contact layer and a distinct thermoplastic polymer first finish-surface layer on the first metallic surface while the metal sheet is presented at a substantially ambient temperature so as to place the first contact layer into direct surface-to-surface contact with the activated first metallic surface, extending the thermoplastic polymer first contact and first finish-surface layers across the width of the metal sheet to establish a first overhang projecting beyond the lateral edges, and permitting the thermoplastic polymers to solidify into a first polymeric coating; co-extruding a maleic anhydride polypropylene thermoplastic polymer second contact layer and a distinct thermoplastic polymer second finish-surface layer on the second metallic surface while the metal sheet is presented at a substantially ambient temperature so as to place the second contact layer into direct surface-to-surface contact with the activated second metallic surface, extending the thermoplastic polymer second contact and finish-surface layers across the width of the metal sheet to establish a second overhang projecting beyond the lateral edges, and permitting the thermoplastic polymers to solidify into a second polymeric coating; trimming the solidified overhangs; melting the first and second polymeric coatings solidified on the metal sheet; and rapidly cooling the first and second polymeric coatings and the metal sheet through glass transition temperatures of the thermoplastic polymers to establish amorphous characteristics throughout the first and second polymeric coatings. 26. The process of claim 25, wherein the metal sheet is selected from low-carbon steel, aluminum, and aluminum/magnesium alloy. 27. The process of claim 25, further comprising continuously traveling the metal sheet in a lengthwise direction during said co-extruding, melting, and rapidly cooling stages. 28. The process of claim 25, further comprising pre-treating the first and second metallic surfaces with heat, and permitting the metallic surfaces to cool to substantially ambient temperature prior to said co-extruding steps. 29. The process of claim 25, wherein ambient temperature is in a range of about 70�� F. to about 90�� F. 30. The process of claim 25, wherein the first and second finish-surface layers comprise a member selected from ethylene polypropylene copolymer, polypropylene homopolymer, and a combination thereof. 31. The process of claim 25, wherein said melting causes the first and second contact layers to fill voids, if any, in the metal sheet. 32. The process of claim 25, wherein said melting improves bonding between the first contact layer and the first finish-surface layer, and improves bonding between the second contact layer and the second finish-surface layer. 33. The process of claim 25, wherein the metal sheet further comprises first and second non-ferrous metallic protective coatings defining the first and second metallic surfaces, respectively. 34. The process of claim 33, wherein the protective coatings are selected from electrolytic plated tin, electrolytic plated chrome/chrome oxide, cathodic dichromate treatment, electrolytic plated zinc, and hot-dip spelter. 35. The process of claim 25, wherein the metal sheet has a thickness in a range of about 5 mils to about 15 mils. 36. The process of claim 25, wherein each of the first and second contact layers and first and second finish-surface layers is about 1 mil to about 2 mils. 37. The process of claim 25, further comprising permitting the metal sheet at ambient temperature to serve as a heat sink so that the first and second coatings solidify on the metal sheet. 38. The process of claim 37, wherein the metal sheet has a thickness in a range of 5 mils to 15 mils.
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