Extruded molten polymeric film bonding of solid polymeric film to flat-rolled sheet metal continuous strip

Abstract

Method steps and apparatus combinations for continuous in-line polymeric coating of rigid corrosion-protected flat-rolled sheet metal continuous-strip substrate utilizing a thermoplastic polymeric material having adhesive characteristics, capable of molten thin-film extrusion for chemical-bonding with an activated-surface of the flat-rolled sheet metal substrate, and substantially-simultaneously bonding with a solid-film polymeric material; establishing multiple-polymer-layers traveling with said activated surface; said solid polymeric film being selected to provide strength, hardness and other desired surface mechanical properties; and, also, providing for external surface coloration, design, weather-proofing, and fabricating capabilities; a second embodiment provides dual-surface multiple-polymeric layer coating carried on by activating and polymeric coating one surface at a time of rigid corrosion-protected flat-rolled sheet metal continuous strip substrate.

1 - 4 . (canceled) 
     
     
         5 . A composite-coated, flat-rolled sheet metal, comprising
 a single-surface coated, rigid flat-rolled sheet metal substrate having a corrosion-protected metallic first surface and an opposite substantially planar second surface, each extending between opposite lateral edges of the sheet metal substrate; and   a coating comprising multiple-polymeric layers, including a thermoplastic extruded tie film and a thermoplastic solid film, the extruded tie layer having adhesive characteristics directly in surface-to-surface contact with the corrosion-protected metallic first surface and being selected from a first group consisting of maleic-anhydride modified polypropylene, maleic anhydride modified low density polyethylene, anhydride-modified ethylene acrylate acid, and acid-modified ethyl methacrylate copolymer, the solid film being on an opposite surface of the tie film and being selected from a second group consisting of polypropylene, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), a combination of PET and PBT, polycarbonates, polyamides polyethylene, polyvinylidene fluoride (PVDF), a combination of polyvinylidene fluoride and a polyacrylic, and polyvinyl fluoride (PVF).   
     
     
         6 . A composite-coated flat-rolled sheet metal, comprising:
 a rigid flat-rolled sheet metal substrate, having a corrosion-protected metallic first surface and a substantially-planar opposite second surface, each extending between opposite lateral edges of the sheet metal substrate;   a first coating comprising first, multiple-polymer-layers, including a thermoplastic extruded tie film and a thermoplastic solid film, the extruded tie film having adhesive characteristics directly in surface-to-surface contact with the corrosion-protected metallic first surface and being selected from a first group consisting of maleic-anhydride modified polypropylene, maleic anhydride modified low density polyethylene, anhydride-modified ethylene acrylate acid, and acid-modified ethyl methacrylate copolymer, the solid film being on an opposite surface of the tie film and being selected from a second group consisting of polypropylene, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), a combination of PET and PBT, polycarbonates, polyamides, polyethylene, polyvinylidene fluoride (PVDF), a combination of polyvinylidene fluoride and a polyacrylic, and polyvinyl fluoride (PVF); and   a second coating on the second surface.   
     
     
         7 . (canceled) 
     
     
         8 . (canceled) 
     
     
         9 . The composite-coated, flat-rolled sheet metal of  claim 5 , wherein the coating extends beyond the opposite lateral edges of the sheet metal substrate to establish overhang portions. 
     
     
         10 . The composite-coated, flat-rolled sheet metal of  claim 5 , wherein the coating is trimmed to be co-extensive with the opposite lateral edges of the sheet metal substrate. 
     
     
         11 . The composite-coated, flat-rolled sheet metal of  claim 5 , wherein the coating has amorphous non-directional characteristics formed by heating the multiple polymeric layers for achieving melt temperature characteristics therein, then cooling the multiple polymeric layers through a glass-transition temperature thereof at a sufficiently rapid rate to form the amorphous non-directional characteristics. 
     
     
         12 . The composite-coated, flat-rolled sheet metal of  claim 5 , wherein the sheet metal substrate is selected from the group consisting of flat-rolled low-carbon steel, flat-rolled aluminum, and flat-rolled aluminum-magnesium alloy. 
     
     
         13 . The composite-coated, flat-rolled sheet metal of  claim 12 , wherein:
 (a) the corrosion protection of the flat-rolled low-carbon steel is a non-ferrous metallic corrosion-protective coating selected from the group consisting of electrolytically-plated tin, electrolytically-plated chrome/chrome oxide, electrolytically-plated cathodic dichromate, dip-coated cathodic dichromate, electrolytically-plated zinc, and hot-dip coated zinc spelter;   (b) the corrosion protection of the flat-rolled aluminum is selected from the group consisting of chemical treatment conversion-coating, electrochemical conversion-coating, chromadizing, and chromate treatment; and   (c) the corrosion protection of the flat-rolled aluminum/magnesium alloy is selected from the group consisting of aluminum oxide, conversion-coating, chromadizing, and chromate treatment.   
     
     
         14 . The composite-coated, flat-rolled sheet metal of  claim 5 , wherein the thermoplastic extruded tie film is chemically bonded at its opposite surfaces to the corrosion-protected metallic first surface and the thermoplastic solid film, respectively. 
     
     
         15 . The composite-coated, flat-rolled sheet metal of  claim 5 , wherein the sheet metal substrate comprises steel having a thickness of about 0.01 inch to about 0.25 inch. 
     
     
         16 . The composite-coated, flat-rolled sheet metal of  claim 5 , wherein the solid film has a first thickness above 0.0005 inch to about 0.006 inch, and wherein the extruded tie film has a second thickness above 10% to about 50% of the first thickness. 
     
     
         17 . The composite-coated, flat-rolled sheet metal of  claim 5 , wherein the second surface is corrosion protected. 
     
     
         18 . The composite-coated, flat-rolled sheet metal of  claim 6 , wherein the first and second coatings extend beyond the opposite lateral edges of the sheet metal substrate to establish overhang portions. 
     
     
         19 . The composite-coated, flat-rolled sheet metal of  claim 6 , wherein the first and second coatings are trimmed to be co-extensive with the opposite lateral edges of the sheet metal substrate. 
     
     
         20 . The composite-coated, flat-rolled sheet metal of  claim 6 , wherein the first and second coatings have amorphous non-directional characteristics formed by heating the multiple polymeric layers for achieving melt temperature characteristics therein, then cooling the multiple polymeric layers through a glass-transition temperature thereof at a sufficiently rapid rate to form the amorphous non-directional characteristics. 
     
     
         21 . The composite-coated, flat-rolled sheet metal of  claim 6 , wherein the sheet metal substrate is selected from the group consisting of flat-rolled low-carbon steel, flat-rolled aluminum, and flat-rolled aluminum-magnesium alloy. 
     
     
         22 . The composite-coated, flat-rolled sheet metal of  claim 21 , wherein:
 (a) the corrosion protection of the flat-rolled low-carbon steel is a non-ferrous metallic corrosion-protective coating selected from the group consisting of electrolytically-plated tin, electrolytically-plated chrome/chrome oxide, electrolytically-plated cathodic dichromate, dip-coated cathodic dichromate, electrolytically-plated zinc, and hot-dip coated zinc spelter;   (b) the corrosion protection of the flat-rolled aluminum is selected from the group consisting of chemical treatment conversion-coating, electrochemical conversion-coating, chromadizing, and chromate treatment; and   (c) the corrosion protection of the flat-rolled aluminum/magnesium alloy is selected from the group consisting of aluminum oxide, conversion-coating, chromadizing, and chromate treatment.   
     
     
         23 . The composite-coated, flat-rolled sheet metal of  claim 6 , wherein the thermoplastic extruded tic film is chemically bonded at its opposite surfaces to the corrosion-protected metallic second surface and the thermoplastic solid film, respectively. 
     
     
         24 . The composite-coated, flat-rolled sheet metal of  claim 6 , wherein the sheet metal substrate comprises steel having a thickness of about 0.01 inch to about 0.25 inch. 
     
     
         25 . The composite-coated, flat-rolled sheet metal of  claim 6 , wherein the solid film has a first thickness above 0.0005 inch to about 0.006 inch, and wherein the extruded tie film has a second thickness above 10% to about 50% of the first thickness. 
     
     
         26 . The composite-coated, flat-rolled sheet metal of  claim 6 , wherein the second surface comprises a corrosion-protected metallic second surface, and wherein the second coating comprises multiple-polymer-layers, including a thermoplastic extruded tie film and a thermoplastic solid film, the extruded tie film having adhesive characteristics directly in surface-to-surface contact with the corrosion-protected metallic second surface and being selected from a first group consisting of maleic-anhydride modified polypropylene, maleic anhydride modified low density polyethylene, anhydride-modified ethylene acrylate acid, and acid-modified ethyl methacrylate copolymer, the solid film being on an opposite surface of the tie film and being selected from a second group consisting of polypropylene, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), a combination of PET and PBT, polycarbonates, polyamides, polyethylene, polyvinylidene fluoride (PVDF), a combination of polyvinylidene fluoride and a polyacrylic, and polyvinyl fluoride (PVF).