Patent ID: 7285200

Claim:
A method for forming a multi-layer composite coating on a continuous metal strip and thereafter forming a coated blank therefrom comprising the following steps: (1) supplying a continuous metal strip having two major surfaces to an entrance of an electrodeposition bath located on a coating line; (2) applying a first electrodepositable coating composition to both major surfaces of the metal strip as it passes through the bath, the metal strip serving as an electrode in an electrical circuit comprising the electrode and a counter-electrode immersed in the first aqueous electrodepositable coating composition, the composition being deposited onto both major surfaces of the metal strip as a substantially continuous electrically conductive coating as electric current is passed between the electrodes; (3) conveying the metal strip from step (2) to a first drying station located on the coating line, and curing the electrically conductive coating as the metal strip passes through the first drying station; (4) optionally, conveying the coated metal strip of step (3) to a recoiling station located off the coating line, and recoiling the coated metal strip; (5) conveying the coated metal strip from step (3) or, optionally step (4) to a second electrodeposition bath located on the coating line; (6) applying a second electrodepositable coating composition to one of the major surfaces of the coated metal strip as it passes through the second electrodeposition bath, the metal strip serving as an electrode in an electrical circuit comprising the electrode and a counter-electrode immersed in the second aqueous electrodepositable coating composition, the composition being deposited onto one of the major surfaces of the coated metal strip as a substantially continuous electrically insulating coating as electric current is passed between the electrodes; (7) conveying the coated metal strip of step (6) to a drying station located on the coating line; (8) curing the electrically insulating coating as the coated metal strip of step (7) passes through the drying station; (9) optionally, transferring the coated metal strip of step (8) to a recoiling station located off the coating line, and recoiling the coated metal strip; (10) transferring the coated metal strip from step (8), or, optionally, step (9) to an entrance of a shear located at an exit end of the drying station; (11) shearing the coated metal strip to form a coated blank as the metal strip passes through the shear; and (12) forming the coated blank of step (11).