Claims
- 1. Composite-coating of elongated flat-rolled sheet metal substrate, comprising
A) supplying elongated flat-rolled rigid sheet-metal substrate by selecting an inorganic-metallic protective coating for each of its pair of substantially-planar opposed surfaces which extend width-wise between longitudinally-extending lateral edges of said substrate, B) controlling substrate movement in the direction of its length; while activating a single inorganic-metallic protected surface of said substrate for enhancing adhesion of extruded molten thermoplastic polymeric material, with such surface-activation being selected from the group consisting of:
(i) impinging an open-flame on said single surface for burning-off light oil and surface debris, if any, while controlling chemical content of said flame for producing an oxidizing reaction on such surface causing loss of surface electrons, (ii) ionizing gas contiguous to said surface by corona-discharge for activating said surface, and (iii) combinations of (i) and (ii), in any order; C) presenting said single activated surface for deposition of an extruded molten film of polymeric materials, including:
(i) a molten thermoplastic polymeric material tie-layer for first-contacting said activated surface, selected from the group consisting of
(a) ethylene glycol modified polyethylene terephthalate (PET) while said activated surface is pre-heated to a temperature of about 230° F. to about 300° F. for to said contact by said tie layer, and (b) anhydride-modified polyethylene while presenting said activated-surface at ambient temperature; and, further including: (ii) a molten thermoplastic polymeric material finish-layer, in overlaying and co-extensive relationship with said tie-layer, selected from the group consisting of
(d) a combination of polybutylene terephthalate (PBT) and polyethylene terephthalate (PET), (e) PBT, and (f) PET; D) preparing said selected polymeric coating materials as separately supplied for each said layer, by
(i) heating said polymeric materials to melt temperature, (ii) pressurizing and continuing heating said molten polymeric materials, while (iii) combining said polymeric materials for simultaneous molten film extrusion; E) controlling travel of said substrate in the direction of its length presenting said single activated surface, while selectively including pre-heating said surface for coverage when said combined tie-layer polymeric material consists essentially of said ethylene glycol modified PET; F) extruding said molten-film polymeric materials under pressure, with
(i) said tie-layer being inner-located for first-contacting said activated surface, and with (ii) said finish-layer being externally located in overlapping and co-extensive relationship with said tie-layer; G) depositing said molten film polymeric materials simultaneously to extend widthwise between lateral edges of said strip, and to extend further
(i) forming a polymeric-overhang of said dual layers extending beyond each lateral-edge of said activated-substrate surface, followed by (ii) removing heat from said polymeric materials
(a) by initial contact of said tie-layer with said substrate surface, (b) by contact of said finish-layer with an in-line temperature-modulating surface, including (c) controlling temperature of said in-line surface, for completing solidification of said polymeric materials; then H) activating the remaining opposed substantially-planar surface of said elongated substrate while traveling in the direction of its length, by carrying-out said steps, as set forth in Paragraph B above, for enhancing adhesion of polymeric materials on said remaining activated surface; I) presenting said activated surface for molten-film extrusion of thermoplastic polymeric materials, as set forth in Paragraph C) above; including J) preparing said polymeric materials for extrusion as set forth in Paragraph D) above; K) controlling travel of said substrate in the direction of its length, as set forth in Paragraph E above; L) presenting said remaining activated-surface for molten-film extrusion coating by said molten polymeric materials, under pressure, as set forth in Paragraph F) above; M) depositing said combined molten polymeric materials with respect to said remaining activated-surface and solidifying said layers as set forth in Paragraph G) above; followed by N) remelting said dual-layer polymeric materials simultaneously on each said surface of said elongated substrate while said substrate is traveling in the direction of its length; including the steps of:
(i) selecting a remelt temperature for both said polymeric layers on each surface, (ii) providing for in-line travel of such substrate in the direction of its length substantially at said remelt temperature, prior to initiating cooling, so as to enable completing coverage by said first-contacting tie-layer with said inorganic-metallic topography on each substrate surface; and, also for (iii) augmenting interlinking of polymeric materials of said tie-layer and said external-finish layer, on each said opposed substrate surface; then O) rapidly cooling said dual-layer polymeric materials substantially-simultaneously on both said opposed surfaces through glass transition temperature, resulting in
(i) establishing amorphous characteristics in said polymeric coating materials on each said opposed surface, while also (ii) cooling said metal substrate to a temperature to avoid later raising said polymeric materials to a glass transition temperature; and Q) directing said elongated substrate, as composite coated on both surfaces, for assembly in a form suitable for transfer.
- 2. The process of claim 1, further including
subsequent to solidification of said polymeric materials as associated with each respective surface, trimming said polymeric overhang as associated with each said surface, and measuring thickness of said dual-layer polymeric materials on each respective surface for maintaining desired uniform coating on each said respective surface.
- 3. The process of claim 2, comprising:
selecting flat-rolled rigid sheet metal substrate from the group consisting of
(i) low-carbon steel, (ii) aluminum, and (iii) aluminum/magnesium alloy.
- 4. The process of claim 3, including
(a) selecting rigid flat-rolled low-carbon steel substrate having a thickness gauge in a range about 0.004″ to about 0.015″, and (b) selecting an inorganic non-ferrous metallic protective coating, for each said opposed substantially-planar surface of said steel substrate, from the group consisting of:
electrolytic plated tin electrolytic-plated chrome/chrome oxide electrolytic-plated zinc cathodic-dichromate, and hot-dip coated zinc spelter.
- 5. The process of claim 3, including
(a) selecting rigid flat-rolled substrate, from the group consisting of
(i) aluminum having a thickness gauge of about 0.005″ to about 0.15″(ii) aluminum magnesium alloy having a thickness gauge of about 0.0045″ and above 0.15″, with (b) an inorganic metallic protective coating for each opposed planar surface selected from the group consisting of
(1) surface oxidation, (2) a chemical conversion coating, (3) an electrochemical conversion coating (4) chromizing, and (5) a chromate coating.
- 6. The process of claim 4, including
(a) selecting flat-rolled low-carbon steel substrate having a hot-dip zinc spelter coating, with spelter coating thickness being in the range of about 0.0005″ to a bout 0.0015″ total both surfaces, and, further (b) selecting, for inclusion in said thermoplastic-polymeric material finish-layer, for at least one substrate surface, an antimicrobial agent selected from the group consisting of:
(i) particulate copper, and (ii) particulate silver encased in zeolite.
- 7. Engineered-composite-coated material, comprising
(a) rigid flat-rolled sheet metal substrate, having opposed substantially planar surfaces, and (b) solidified polymeric-coating materials, produced with polymeric overhang at each lateral edge, which is trimmed for measuring polymeric coating thickness on each said planar surface of said substrate, in accordance with the process of claim 3.
- 8. Engineered-composite-coated material, comprising
(a) rigid flat-rolled low-carbon steel substrate, having opposed substantially planar surfaces, with (b) non-ferrous inorganic-metallic protective coating on each surface, produced in accordance with the process of claim 4.
- 9. Engineered-composite-coated-material, comprising
(a) rigid flat-rolled sheet metal substrate with inorganic metallic protective coating on each opposed planar surface, produced in accordance with the process of claim 5.
- 10. Engineered-composite-coated material, comprising
(a) hot-dip zinc spelter coated elongated rigid flat-rolled low-carbon steel substrate; presenting (b) solidified polymeric material as an externally-located finish-layer on each such surface; in which, at least one said externally-coated finish-layer, includes (c) an antimicrobial agent established in accordance with process of claim 6.
- 11. In-line apparatus for molten polymeric film extrusion-coating of elongated flat-rolled sheet metal, comprising:
A) means supplying elongated flat-rolled rigid sheet-metal substrate, traveling in-line in the direction of its length, with both substantially-planar opposed presenting an inorganic-metallic protective surface extending width-wise between longitudinally-extending lateral edges of said strip; B) in-line means for activating a single such substrate surface at-a-time in preparation for molten film polymeric extrusion coating of such single activated surface, in which
(i) said surface-activation means are selected from the group consisting of:
(a) means impinging controlled-content open-flame on said single surface for burn-off of light surface oil and associated surface debris, if any, while producing an oxidizing reaction causing loss of surface electrons, for enhanced polymeric adhesion, (b) corona-discharge means for ionizing gas contiguous to said single surface, free of electric arcing, for activating said surface for enhanced polymeric adhesion, and (c) combinations of (a) and (b), in any order; C) means for presenting such substrate for adherence of molten-film extruded thermoplastic polymeric materials to said single activated surface for travel with said elongated substrate, including:
(i) means for supplying a pair of distinct thermoplastic polymeric formulations capable of compatible combined simultaneous molten film extrusion, so as to present a thermoplastic inner-located tie-layer and an externally-located thermoplastic finish layer; with (ii) said tie-layer in said simultaneous extrusion being selected from the group consisting of:
(a) ethylene glycol modified polyethylene terephthalate (PET), by utilizing in-line pre-heating means to establish said activated-surface at a temperature in the range of about 230° F. to about 300° F., for desired surface coverage by said tie-layer polymeric material, and (b) anhydride-modified polyethylene, with said activated surface being presented at ambient temperature; with D) said finish-layer thermoplastic polymeric material being selected from the group consisting of:
(i) a combination of polybutylene terephthalate (PBT) and polyethylene terephthalate (PET), (ii) PBT, and (iii) PET; E) polymeric material handling means for receiving said polymeric materials, melting said selected tie-layer and finish-layer thermoplastic polymeric materials, and combined heating and pressurizing of said tie-layer and finish-layer polymeric materials for simultaneous molten-film extrusion; F) extrusion means for said combined polymeric materials, including
(i) die means presenting a extended-length narrow nozzle opening for molten-film extrusion of said combined molten pressurized polymeric materials, with said nozzle-opening being oriented, so as (ii) to extend widthwise of said substrate to each lateral edge of such substrate, and to extend further so as to (iii) establish polymeric overhang, of said combined polymeric materials, beyond each said lateral edge of said surface, in which (iv) said tie-layer of said combined extruded-film polymeric materials is located so as to initially contact said activated-surface, and (v) said finish-layer is located, externally, of said combined polymeric materials, coextensive with said tie-layer; G) in-line heat removal means for said combined polymeric materials, including
(i) initial contact of said tie-layer with said activated surface; (ii) in-line rotatable roll means presenting a peripheral-surface for contact by said externally-located finish-layer of said extruded polymeric materials, during in-line travel of said substrate in the direction of its length, and (iii) means for cooling said peripheral-surface of said roll means for completing solidification of said combined polymeric materials by said in-line contact of said peripheral surface; H) (i) in-line edge trimmer means for removing solidified polymeric overhang along each lateral edge, while said elongated substrate is traveling in the direction of its length, and,
(ii) subsequently located in-line means for measuring polymeric thickness on said single-activated surface, so as to enable maintaining uniform polymeric thickness, during in-line operations; subsequently located I) in-line means for activating solely the remaining opposed substantially-planar surface of said substrate, in which
(i) surface pre-treating means are selected from the group as set forth in Paragraph B above, while (ii) said strip is traveling in the direction of its length; J) means presenting said remaining surface as activated for receiving tie-layer polymeric materials, selected as set forth in Paragraph C) above; with K) means for delivering finish-layer polymeric materials selected as set forth in Paragraph D) above; L) polymeric handling means for separately receiving and melting said polymeric materials for said layers, and heating and pressurizing polymeric materials in combination for said layers, as set forth in Paragraph E) above, M) thin-film extrusion means for said combined polymeric materials, including die means with an extended-length nozzle-opening, oriented for molten film extrusion widthwise extending across said substrate activated surface, and, extending further, to establish polymeric overhang along each lateral edge of said substrate, as set forth in Paragraph F) above; N) in-line heat-removal means including rotatable roll means presenting a cooled peripheral surface, as set forth in Paragraph G) above, for solidification of said polymeric materials; O) (i) in-line edge trimmer means for removal at each lateral edge of solidified polymeric overhang, during travel of said substrate in the direction of its length; and
(ii) in-line means for measuring polymeric coating thickness on said surface for maintaining uniform polymeric coating thickness during in-line operations; and P) finishing-processing means for polymeric materials on each said substrate surface, including
(i) polymer remelting means, including high-frequency induction heating means for surface heating of said substrate, while traveling in the direction of its length, so as to heat said polymeric materials on each said surface of said substrate to establish melt temperature characteristics, and (ii) means providing for travel of said polymeric-coated substrate with said established melt temperature characteristics for said polymeric materials, prior to initiating cooling, so as to:
(a) facilitate completing surface coverage, by said tie-layer with said activated-surface topography on each said surface, and (b) augment polymeric interlinking of said coextensive finish-layer with said tie-layer on each said surface; followed by R) cooling means, including quench bath means for rapidly cooling said polymeric materials associated with each said metallic surface through glass transition temperature, for producing substantially-amorphous characteristics in said dual-layer polymeric materials on each surface, and S) means for preparing said dual-surface polymeric-coated substrate for transfer.
- 12. The continuous-in-line apparatus of claim 11, including means for supplying inorganic-metallic protective-coated rigid flat-rolled sheet metal substrate, selected from the group consisting of
(i) low-carbon steel, (ii) aluminum, and (iii) aluminum/magnesium alloy; in which:
(a) said sheet metal supply means delivers flat-rolled low-carbon steel substrate having a thickness gauge in a range of about of about 0.004″ to about 0.015″, including (b) a non-ferrous, inorganic-metallic protective coating, capable of being activated or enhanced polymeric adhesion, on each opposed substantially-planar surface of said steel substrate, selected from the group consisting of:
electrolytic tinplate electrolytic-plated chrome/chrome oxide electrolytic-plated zinc cathodic dichromate, and hot-dipped zinc spelter.
- 13. The continuous-in-line apparatus process of claim 12, including
(i) supply means for flat-rolled low-carbon steel substrate having a hot-dipped zinc spelter coating, and, in which (ii) said external-finish polymeric layer, on at least one of said opposed surfaces, includes an antimicrobial agent selected from the group consisting of (i) particulate copper, and (ii) particulate silver encased in zeolite.
- 14. The apparatus of claim 12, including means for supplying flat-rolled sheet metal selected from the group consisting of
(i) aluminum having a thickness gauge range of about 0.005″ to about 0.15″, and
(ii) aluminum/manganese alloy, having a thickness gauge of about 0.0045″ to about 0.15″, with (iii) each said substrate surface having an inorganic-metallic protective coating, selected from the group consisting of
(a) a surface oxide of said selected sheet metal, (b) a chemical conversion coating, (c) an electrochemical conversion coating, (d) a chromizing coating, and (e) a chromate coating.
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/468,705 filed May 7, 2003; and, is a continuation-in-part of co-owned and co-pending U.S. patent application Ser. No. 10/156,471 entitled “METHODS AND APPARATUS FOR SURFACE PREPARATION AND DUAL POLYMERIC LAYER COATING OF CONTINUOUS-STRIP FLAT-ROLLED SHEET METAL, AND COATED PRODUCT” filed May 28, 2002 and of co-owned and co-pending U.S. patent application Ser. No. 10/191,411 entitled “PROCESSING AND APPARATUS FOR PRODUCTION OF ENGINEERED COMPOSITE COMBINING CONTINUOUS-STRIP SHEET METAL AND THERMOPLASTIC POLYMERS”, filed Jul. 9, 2002 as a continuation-in-part of co-owned U.S. patent application Ser. No. 10/156,473 (now abandoned), filed May 28, 2002, entitled “PROCESSING AND APPARATUS FOR PRODUCTION OF ENGINEERED COMPOSITE COMBINING CONTINUOUS-STRIP SHEET METAL AND THERMOPLASTIC POLYMERS”, as a continuation-in-part of co-owned (now abandoned) U.S. patent application Ser. No. 09/767,785, entitled “POLYMERIC COATED METAL STRIP AND METHOD FOR PROCESSING SAME”, filed Jan. 23, 2001 as a continuation-in-part of co-owned (now abandoned) U.S. patent application Ser. No. 09/490,305 entitled, “POLYMERIC COATED METAL AND METHOD FOR PRODUCING SAME”, filed Jan. 24, 2000.
Provisional Applications (1)
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Number |
Date |
Country |
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60468705 |
May 2003 |
US |
Continuation in Parts (1)
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Number |
Date |
Country |
Parent |
10156471 |
May 2002 |
US |
Child |
10841723 |
May 2004 |
US |