Roll coating-based preparation methods for adhesive bonding of aluminum alloys, and products relating to the same

A method comprising:

• (a) preparing an aluminum alloy product for roll coating having an upper surface and a lower surface, wherein the preparing comprises:
• (i) contacting the aluminum alloy product with an alkaline cleaning solution;
• (ii) first rinsing the aluminum alloy product;
• (iii) contacting the aluminum alloy product with an acidic solution;
• and
• (iv) second rinsing the aluminum alloy product;
• (b) roll coating an aqueous functionalization solution onto the upper surface and the lower surface of the prepared aluminum alloy product, wherein the roll coating comprises:
• (i) contacting an upper surface of the prepared aluminum alloy product with a first roller, wherein the first roller is in liquid communication with a first bath comprising a first aqueous functionalization solution having a first concentration of active ingredients;
• and
• (ii contacting a lower surface of the prepared aluminum alloy product with a second roller, wherein the second roller is in liquid communication with a second bath comprising a second aqueous functionalization solution having a second concentration of the active ingredients;
• (c) drying the roll coated aluminum alloy product, wherein the drying includes maintaining a peak metal temperature from 150° F. to 300° F.;
• wherein the active ingredients comprises a monomer component and a copolymer component;
• wherein the first concentration of the active ingredients of the first aqueous functionalization solution is from 0.1-4.75 wt. %;
• wherein the second concentration of the active ingredients of the second aqueous functionalization solution is from 0.35-5.0 wt. %;
• wherein the first concentration is at least 0.25 wt. % less than the second concentration of active ingredients;
• wherein, at least partially due to the first concentration, the upper surface of the aluminum alloy product realizes a post-drying coating weight of from 0.21 to 3.55 mg/m2;
• wherein, at least partially due to the second concentration, the lower surface of the aluminum alloy product realizes a post-drying coating weight of from 0.21 to 3.55 mg/m2;
• wherein the first aqueous functionalization solution comprises a first ratio of the monomer component to the copolymer component, wherein the first ratio of the monomer component to the copolymer component is from 1:19 to 7:13 (monomer component:
• copolymer component);
• wherein the second aqueous functionalization solution comprises a second ratio of the monomer component to the copolymer component, wherein the second ratio of the monomer component to the copolymer component is different than the first ratio.