Abstract: Methods and apparatus for producing composite-coated rigid flat-rolled sheet metal substrate in which thermoplastic polymeric materials are selected and combined for dual-layer molten-film extrusion presenting a first-contacting tie-layer and an externally-located finish-layer which are simultaneously extruded for a single substrate surface at-a-time; in which tie-layer selection includes an ethylene-glycol modified PET, requiring a substrate-surface temperature between 230° F. and 300° F.

Abstract: Methods and apparatus for producing composite-coated rigid flat-rolled sheet metal substrate in which thermoplastic polymeric materials are selected and combined for dual-layer molten-film extrusion presenting a first-contacting tie-layer and an externally-located finish-layer which are simultaneously extruded for a single substrate surface at-a-time; in which tie-layer selection includes an ethylene-glycol modified PET, requiring a substrate-surface temperature between 230° F. and 300° F.

Abstract: 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.

Abstract: 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.

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.

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 a work-product embodiment with multiple-polymer-layers traveling with the single activated surface; and, on which the solid polymeric film is selected to provide strength, hardness and other desired surface mechanical properties which also provide 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.

Abstract: Flat-rolled steel strip, free of surface iron oxide, is provided with a corrosion-protective metallic coating on both surfaces, followed by continuous-line polymer coating operations in which a single surface is pre-treated so as to activate that surface for adhesion of molten extruded thin-film polymeric materials for in-line travel. Polymeric materials are formulated to provide maleic-anhydride modified polypropylene which is melted and pressurized for extrusion as a molten thin-film tie-layer for first contacting that activated surface; and, thin-film intermediate and finish layers are each formulated to contain a selected percentage of polybutylene; which are extruded as molten films in overlaying relationships to said first contacting tie-layer.

Abstract: Engineered composite coated flat-rolled steel strip is produced in continuous line operations, in which flat-rolled steel strip, free of surface iron oxide, having a metallic corrosion-protective coating, is polymer coated in continuous-line operations in which a plurality of adherent thin-film layers of polymeric material are deposited on a strip surface. In a dual-surface polymeric coating embodiment, each surface is separately-pretreated for surface adhesion, solidified, and polymeric overhang is removed. Finish processing re-melts the polymer coating and rapidly cools that coating through glass-transition temperature to establish amorphous characteristics in the polymeric coating materials. An anhydride-modified polypropylene, first contacts the strip, an intermediate layer can include about fifteen to twenty five percent, by weight, polybutylene with the balance polypropylene; an outer surface polymeric layer includes about five to ten percent, by weight, polybutylene with the balance polypropylene.

Abstract: A process is provided for making a composite work article suitable for fabricating rigid sheet metal can components. A steel sheet having first and second surfaces is pre-treated to enhance reception and retention of a multi-layer polymer coating on the pre-treated first surface. The multi-layer polymer coating is melt extruded on the pre-treated first surface and beyond opposite lateral edges of the work article to establish overhang portions, then solidified. The multi-layer polymeric coating has a tie polymeric layer contacting the pre-treated first surface, and a finish-surface polymeric layer.

Abstract: Engineered composite coated flat-rolled steel strip is produced in continuous line operations, in which flat-rolled steel strip, free of surface iron oxide, having a metallic corrosion-protective coating, is polymer coated in continuous-line operations in which a plurality of adherent thin-film layers of polymeric material are deposited on a strip surface. In a dual-surface polymeric coating embodiment, each surface is separately-pretreated for surface adhesion, solidified, and polymeric overhang is removed. Finish processing re-melts the polymer coating and rapidly cools that coating through glass-transition temperature to establish amorphous characteristics in the polymeric coating materials. An anhydride-modified polypropylene, first contacts the strip, an intermediate layer can include about fifteen to twenty five percent, by weight, polybutylene with the balance polypropylene; an outer surface polymeric layer includes about five to ten percent, by weight, polybutylene with the balance polypropylene.

Abstract: A process is provided for making a composite work article suitable for fabricating rigid sheet metal can components. A steel sheet having first and second surfaces is pre-treated to enhance reception and retention of a multi-layer polymer coating on the pre-treated first surface. The multi-layer polymer coating is melt extruded on the pre-treated first surface and beyond opposite lateral edges of the work article to establish overhang portions, then solidified. The multi-layer polymeric coating has a tie polymeric layer contacting the pre-treated first surface, and a finish-surface polymeric layer.

Abstract: Methods and apparatus for producing composite-coated rigid flat-rolled sheet metal substrate in which thermoplastic polymeric materials are selected and combined for dual-layer molten-film extrusion presenting a first-contacting tie-layer and an externally-located finish-layer which are simultaneously extruded for a single substrate surface at-a-time; in which tie-layer selection includes an ethylene-glycol modified PET, requiring a substrate-surface temperature between 230° F. and 300° F.

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 a work-product embodiment with multiple-polymer-layers traveling with the single activated surface; and, on which the solid polymeric film is selected to provide strength, hardness and other desired surface mechanical properties which also provide 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.

Abstract: Flat-rolled steel strip, free of surface iron oxide, is provided with a corrosion-protection metallic coating on both surfaces, followed by continuous-line polymeric coating operations in which a single surface is pre-treated so as to activate that surface for adhesion of molten extruded thin-film polymeric material for in-line travel. Polymeric materials are formulated to provide maleic-anhydride modified polypropylene, which is melted and pressurized for extrusion as a molten thin-film tie-layer for first contacting that activated surface; and, thin-film intermediate and finish layers are each formulated to contain a selected percentage of polybutylene; which are extruded as molten films in overlaying relationship to said first contacting tie-layer.

Abstract: Specific materials, percentages, dimensions, and other values have been set forth for purposes of presenting specific embodiments enabling one skilled in the art to make and use the invention. However, it should be recognized that the above description and disclosures of specific embodiments, along with descriptions of combinations of materials, percentages, dimensions and other values set forth in the above specification, provide technical information enabling those skilled in the art to arrive at other values, while continuing to rely on the principles of the invention as taught by the above specification.

Abstract: Engineered composite coated flat-rolled steel strip is produced in continuous line operations, in which flat-rolled steel strip, free of surface iron oxide, having a metallic corrosion-protective coating, is polymer coated in continuous-line operations in which a plurality of adherent thin-film layers of polymeric material are deposited on a strip surface. In a dual-surface polymeric coating embodiment, each surface is separately-pretreated for surface adhesion, solidified, and polymeric overhang is removed. Finish processing re-melts the polymer coating and rapidly cools that coating through glass-transition temperature to establish amorphous characteristics in the polymeric coating materials. An anhydride-modified polypropylene, first contacts the strip, an intermediate layer can include about fifteen to twenty five percent, by weight, polybutylene with the balance polypropylene; an outer surface polymeric layer includes about five to ten percent, by weight, polybutylene with the balance polypropylene.

Abstract: Processes and apparatus for manufacturing an engineered-composite combining rigid flat-rolled sheet metal continuous-strip and selected polyester thermoplastics, which are formed into distinct polymeric layers for melted extrusion deposition on a single surface, at a time, using pressure dies, and other steps, for forming a uniform coat of distinct polymeric layers, which provide high green-strength-adhesion during continuous-in-line travel; and including dual-surface finishing for complete bonding of the polymeric layers on both metallic surfaces.

Abstract: 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.

Abstract: Methods and apparatus enabling simultaneous electrolytic tinplating of bottom and top surfaces of continuous-strip flat-rolled steel substrate while moving in the direction of its length, are disclosed. Both surfaces are plated in a first cell of a multi-cell horizontally-oriented tinplating line. The stannous ion plating source and the source of electrical power, for each surface, differ. Tin pellets for an upper surface anode are confined in a solution-permeable material confined, within an electrically-conductive lining. Dissolution of surface iron from the steel strip is substantially eliminated, improving the stannous ion plating solution quality, eliminating requirements for harmful additives, and increasing the variety of electrolytically tinplated continuous-strip steel products and processes.

Abstract: The present invention is a process for continuous extrusion coating the surfaces of a metal strip which includes the steps of moving said metal strip by means of a plurality of rolls. The strip then has impinged on its first and second surfaces to be coated an oxidizing flame. The first surface passes through a corona discharge and extruded on to the first surface is a melted polymeric extrudiate. Thereafter, the surface is passed over a chill roll having a temperature less than said extrudiate to provide a first coated surface. The second surface is then subjected to a oxidizing flame and corona discharge and a melted polymeric extrudiate is extruded on to the second surface. Thereafter, the second surface is passed over a chill roll having a temperature less than said extrudiate to provide a second coated surface. The coated strip is then reheated to about the melt temperature of said extrudiates and quenched to provide an extrusion coated strip of the present invention.