Polymer coated metallic substrate and method for making

1. A method of making a composite material comprising a coating and a metallic substrate, the method comprising the steps of:

(a) applying a polymer composition to at least one side of the metallic substrate using a technique of manifold flooding and squeegee rolling, or roll coating;

wherein the polymer composition comprises acrylic or styrene-acrylic based polymer:

i. having a molecular weight of greater than 50,000;

ii. having a glass transition temperature (Tg) of 65-80° C.; and

iii. comprising 90-100 wt. % of total solids in the polymer composition;

(b) forming the polymer composition into a continuous wet film on the at least one side of the metallic substrate which is traveling at up to 600 feet per minute; and

(c) drying the continuous wet film to form the coating having a uniform dried thickness of less than about 0.2 mils.

2. The method of claim 1 , wherein the composite material is formable into a 1 inch deep drawn modified Swift cup without galling, flaking, peeling or powdering.

3. The method of claim 1 , wherein the polymer composition is applied to the metallic substrate at a wet thickness of between 100 to 400 milligrams per square foot of the metallic substrate.

4. The method of claim 3 , wherein the continuous wet film is air dried in less than 5 seconds to produce a coating with a pencil hardness of H minimum according to ASTM D3363.

5. The method of claim 1 , wherein the coating has a uniform dried thickness of from 0.05 to 0.1 mils.

6. The method of claim 1 , wherein the coating is removable from the metallic substrate with an alkaline solution.

7. The method of claim 1 , wherein the coating is not chemically cured.

8. The method of claim 1 , wherein the coating does not comprise forming or stamping lubricants.

9. The method of claim 1 , wherein the dried coating weight of the composite material is 50 to 350 milligrams of coating per square foot of the metallic substrate.

10. The method of claim 1 , wherein the polymer composition further comprises one or more of the following additives:

(a) a plasticizer selected from the group consisting of phosphate esters, phthalate esters, benzoic acid esters, and fatty acid esters;

(b) a coalescing agent selected from alkyl or aromatic ethers of ethylene glycol or propylene glycol;

(c) paraffin, polyethylene or polyolefin wax additives;

(d) alkali soluble resins selected from the group consisting of rosin adduct;

(e) polyvalent metal ions;

(f) defoamers;

(g) tints/colorants;

(h) micron or nano sized particulate; wherein the particulate is selected from the group consisting of silver, cesium, silicon, or rare earth elements.

11. The method of claim 1 , wherein adhesion of the coating to the metallic substrate is rated 5B when tested according to ASTM D3359.

12. A method of making a composite material comprising a coating and a metallic substrate, the method comprising the steps of:

(a) applying an emulsion or dispersion comprising spherical particles of acrylic or styrene-acrylic based polymers to at least one side of the metallic substrate, using a technique of manifold flooding and squeegee rolling, or roll coating, wherein the acrylic or styrene-acrylic based polymers have glass transition temperature (Tg) of 50-80° C. and a molecular weight of from 125,000 to 1,000,000;

(b) forming the emulsion or dispersion into a continuous wet film on the at least one side of the metallic substrate which is traveling at up to 600 feet per minute; and

(c) drying the continuous wet film to form the coating having a uniform dried thickness of less than about 0.2 mils;

wherein, the composite material is formable into a 1 inch deep drawn modified Swift cup without galling, flaking, peeling or powdering.

13. The method of claim 12 , wherein the continuous wet film is air dried in less than 5 seconds to produce a coating with a pencil hardness of H minimum according to ASTM D3363.

14. The method of claim 12 , wherein coating has a uniform dried thickness of from 0.05 to 0.1 mils.

15. The method of claim 12 , wherein the coating is not chemically cured.

16. The method of claim 12 , wherein the polymer composition additionally comprises one or more of the following additives:

(a) a plasticizer selected from the group consisting of phosphate esters, phthalate esters, benzoic acid esters, and fatty acid esters;

(b) a coalescing agent selected from alkyl or aromatic ethers of: ethylene glycol or propylene glycol;

(c) paraffin, polyethylene or polyolefin wax additives;

(d) alkali soluble resins selected from the group consisting of rosin adduct;

(e) polyvalent metal ions;

(f) defoamers;

(g) tints/colorants;

(h) micron or nano sized particulate; wherein the particulate is selected from the group consisting of silver, cesium, silicon, or rare earth elements.

17. The method of claim 12 , wherein adhesion of the coating to the metallic substrate is rated 5B when tested according to ASTM D3359.

18. A method of making a composite material comprising a coating and a metallic substrate, the method comprising the steps of:

(a) applying a polymer composition to at least one side of the metallic substrate via manifold flooding and squeegee rolling, wherein the polymer composition comprises an acrylic or styrene-acrylic based polymer, wherein the polymer:

1. has a molecular weight of from 125,000 to 1,000,000;

2. has a glass transition temperature (Tg) of 50-80° C.; and

3. comprises 90-100 wt. % of total solids in the polymer composition;

b) forming a continuous wet film on the at least one side of the metallic substrate when the metallic substrate travels at up to 600 feet per minute; and

c) drying the continuous wet film to form the coating, wherein the coating:

i. has a uniform dried thickness of less than about 0.2 mils;

ii. has a pencil hardness of H minimum according to ASTM D3363; and

iii. is formable into a 1 inch deep drawn modified Swift cup without galling, flaking, peeling or powdering; and

iv. is bendable to a OT radius (ASTM 4145) without galling, flaking, peeling, or powdering.