Coated sheet metal and method of forming products therefrom

Claim 2

In a process for drawing and ironing a coated metallic sheet into seamless containers, the method which consists essentially of the steps of: (a) providing a metallic sheet, (b) applying a coating of thermosetting organic material to the surface of the metallic sheet, and (c) subjecting the coating of thermosetting organic material to a temperature for a time to effect a cure of the coating in the range of between about 1% and about 75% MEK insoluble residue, which cure provides a bond between the coating and the metallic sheet and a coating with sufficient extensibility to draw and iron the coated metallic sheet into a seamless container without further treatment of the coating.

Claim 3

In a process for drawing and ironing a coated metallic sheet according to claim 1 wherein the metallic sheet is selected from the group consisting of blackplate, electrolytic chromium-coated container steel, tinplate and aluminum.

Claim 4

In a process for drawing and ironing a coated metallic sheet according to claim 1 wherein the coating of thermosetting organic material includes an internal lubricant.

Claim 5

In a process for drawing and ironing a coated metallic sheet according to claim 1 wherein the thermosetting organic material is selected from the group consisting of epoxy phenolic, epoxy urea formaldehyde and thermosetting vinyl.

Claim 6

In a process for drawing and ironing a coated metallic sheet according to claim 1 wherein the coating has sufficient extensibility to allow a reduction of about 70% in sidewall thickness during ironing of the coated metallic sheet into a seamless container.

Claim 9

A method of forming a coated seamless container according to claim 6 wherein the thermosetting organic coating includes an internal lubricant.

Claim 10

A method of forming a coated seamless container according to claim 6 wherein the sheet metal is selected from the group consisting of blackplate, electrolytic chromium-coated container steel, tinplate and aluminum.

Claim 11

A method of forming a coated seamless container according to claim 6 wherein the organic coating is selected from the group consisting of epoxy phenolic, epoxy urea formaldehyde and thermosetting vinyl.

Claim 12

A method of forming a coated seamless container according to claim 9 wherein the sheet metal is blackplate.

Claim 13

A method of forming a coated seamless container according to claim 6 wherein the sidewall thickness is reduced by about 70% during the ironing of the cup preform.

Claim 14

In a process for drawing and ironing a coated metallic sheet into seamless containers, the method which consists essentially of the steps of: (a) providing a metallic sheet, (b) applying to the surface of the metallic sheet a coating of thermosetting organic material selected from the group consisting of: (i) an epoxy phenolic comprising approximately: 33% by weight solids consisting of about: 155 parts by weight epichlorohydrin bisphenol A epoxy resin (medium molecular weight) 45 parts by weight allyl ether of methylol phenol resin 1 part by weight phosphoric acid catalyst, and 67% by weight solvent consisting of about: 5 parts by weight iso-butanol 9 parts by weight xylene 4 parts by weight pentoxone 4 parts by weight diacetone alcohol 4 parts by weight isophorone 7 parts by weight mesityl oxide, (ii) an epoxy phenolic comprising approximately:

Claim 15

In a process for drawing and ironing a coated metallic sheet into seamless containers, the method which consists essentially of the steps of: (a) providing a metallic sheet, (b) applying to the surface of the metallic sheet a coating of thermosetting organic material selected from the group consisting of: (i) an epoxy phenolic comprising approximately: 33% by weight solids consisting of about: 155 parts by weight epichlorohydrin bisphenol A epoxy resin (medium molecular weight) 45 parts by weight allyl ether of methylol phenol resin 1 part by weight phosphoric acid catalyst, and 67% by weight solvent consisting of about: 5 parts by weight iso-butanol 9 parts by weight xylene 4 parts by weight pentoxone 4 parts by weight diacetone alcohol 4 parts by weight isophorone 7 parts by weight mesityl oxide, (ii) an epoxy phenolic comprising approximately:

Claim 16

5% by weight solids consisting of about: 3 parts by weight epichlorohydrin bisphenol A resin (medium molecular weight) 2 parts by weight xylenol formaldehyde resin, and 67.5% by weight solvent consisting of about: 2 parts by weight cellosolve acetate 1 part by weight butanol 1 part by weight xylene 10 parts by weight methyl iso-butyl ketone 6 parts by weight cellosolve, (iii) an epoxy urea formaldehyde comprising approximately: 38% by weight solids consisting of about: 225 parts by weight epichlorohydrin bisphenol A epoxy resin (medium molecular weight) 39 parts by weight urea-formaldehyde resin (50% solids in 1/1 butanol/xylene) 6 parts polyvinyl butyral, 62% by weight solvent consisting of about: 2 parts by weight butanol 4 parts by weight xylene 12 parts by weight cellosolve acetate 5 parts by weight low boiling aromatic naphtha 2 parts by weight nitropropane 6 parts by weight pine oil 5 parts by weight isophorone, and (iv) a thermosetting vinyl comprising approximately: 22% by weight solids consisting of about: 7 parts by weight vinyl solution resin (91% vinyl chloride, 3% vinyl acetate, 6% vinyl alcohol) 2 parts by weight epichlorohydrin bisphenol A epoxy resin (low molecular weight) 1 part by weight urea formaldehyde resin, and 78% by weight solvent consisting of about: 10 parts by weight high boiling aromatic naphtha 8 parts by weight isophorone 1 part by weight methyl iso-butyl ketone 1 part by weight butanol, and (c) subjecting the coating of thermosetting organic material to a temperature for a time to effect a cure of the coating in the range of between about 1% and about 75% MEK insoluble residue, which cure provides a bond between the coating and the metallic sheet and a coating with sufficient extensibility to draw and iron the coated metallic sheet into a seamless container without further treatment of the coating.

Claim 17

5% by weight solids consisting of about: 3 parts by weight epichlorohydrin bisphenol A resin (medium molecular weight) 2 parts by weight xylenol formaldehyde resin, and 67.5% by weight solvent consisting of about: 2 parts by weight cellosolve acetate 1 part by weight butanol 1 part by weight xylene 10 parts by weight methyl iso-butyl ketone 6 parts by weight cellosolve, (iii) an epoxy urea formaldehyde comprising approximately: 38% by weight solids consisting of about: 225 parts by weight epichlorohydrin bisphenol A epoxy resin (medium molecular weight) 39 parts by weight urea-formaldehyde resin (50% solids in 1/1 butanol/xylene) 6 parts polyvinyl butyral, 62% by weight solvent consisting of about: 2 parts by weight butanol 4 parts by weight xylene 12 parts by weight cellosolve acetate 5 parts by weight low boiling aromatic naphtha 2 parts by weight nitropropane 6 parts by weight pine oil 5 parts by weight isophorone, and (iv) a thermosetting vinyl comprising approximately: 22% by weight solids consisting of about: 7 parts by weight vinyl solution resin (91% vinyl chloride, 3% vinyl acetate, 6% vinyl alcohol) 2 parts by weight epichlorohydrin bisphenol A epoxy resin (low molecular weight) 1 part by weight urea formaldehyde resin, and 78% by weight solvent consisting of about: 10 parts by weight high boiling aromatic naphtha 8 parts by weight isophorone 1 part by weight methyl iso-butyl ketone 1 part by weight butanol, and (c) subjecting the coating of thermosetting organic material to a temperature for a time to effect a cure of the coating in the range of between about 1% and about 75% MEK insoluble residue, which cure provides a bond between the coating and the metallic sheet and a coating with sufficient extensibility to draw and iron the coated metallic sheet into a seamless container without further treatment of the coating.

Claim 18

In a process for drawing and ironing a coated metallic sheet according to claim 12 wherein the metallic sheet is selected from the group consisting of blackplate, electrolytic chromium-coated container steel, tinplate and aluminum.

Claim 19

In a process for drawing and ironing a coated metallic sheet according to claim 12 wherein the coating of thermosetting organic material includes an internal lubricant.

Claim 20

In a process for drawing and ironing a coated metallic sheet according to claim 12 wherein the coating has sufficient extensibility to allow a reduction of 70% in sidewall thickness during ironing of the coated metallic sheet into a seamless container.