METHOD OF SURFACE COATING TO ENHANCE DURABILITY OF AESTHETICS AND SUBSTRATE COMPONENT FATIGUE

• US 20090162544A1
• Filed: 12/20/2007
• Published: 06/25/2009
• Est. Priority Date: 12/20/2007
• Status: Abandoned Application

• Current Assignee: Alcoa Incorporated (Howmet Aerospace, Inc.)
• Original Assignee: Alcoa Incorporated (Howmet Aerospace, Inc.)
• Inventors: Finn, Kellen M., Hrabusa, Joseph, Garesche, Carl E.
• Application Number:
  US11/961,560
• Publication Number:
  US 20090162544A1
• Time in Patent Office: Days
• US Class Current: 427/202
• CPC Class Codes: B05D 5/067 Metallic effect
• CPC Class Codes: B05D 7/16 using synthetic lacquers or varnishes
• CPC Class Codes: B05D 7/53 Base coat plus clear coat type

Abstract

A method for surface coating products, especially vehicle wheels, to improve the durability of their aesthetics and structural integrity via increased resistance to impact, abrasion, soil (e.g., brake dust), corrosion and fatigue stresses. The method comprises applying a uniform clear coating layer to the surface of the substrate, and then applying a preceramic resin film to the coated substrate, where the preceramic resin film is uniformly applied and cured onto the coated substrate so as to result in a ceramic shell of about 3 microns to about 12 microns in thickness over the coated substrate. In another embodiment, the method for the surface coating of an aluminum alloy substrate comprises applying a uniform clear coating layer to the surface of the aluminum alloy substrate and then applying a preceramic resin film to the coated aluminum alloy substrate, where the preceramic resin film is uniformly applied and cured onto the coated aluminum alloy substrate so as to result in a ceramic shell of about 3 microns to about 12 microns in thickness over the coated aluminum alloy substrate.

Claims

1. A method for treating a substrate, the method comprises:

applying a uniform clear coating layer to the surface of the substrate; and

then applying a preceramic resin film to the coated substrate,

wherein the preceramic resin film is uniformly applied and cured onto the coated substrate so as to result in a ceramic shell of about 3 microns to about 12 microns in thickness over the coated substrate.

2. The method of claim 1, wherein the surface of the substrate is pretreated before the uniform clear coating layer is applied to the surface of the substrate.

3. The method of claim 1, wherein after applying the uniform clear coating layer to the surface of the substrate, the clear coating layer is then cured onto the surface of the substrate.

4. The method of claim 1, wherein after applying the preceramic resin film to the coated substrate, the clear coating layer and the preceramic resin film are simultaneously cured onto the substrate.

5. The method of claim 1, wherein the substrate is made of a metal.

6. The method of claim 5, wherein the metal is selected from the group consisting of aluminum, steel, magnesium and titanium.

7. The method of claim 6, wherein the metal is a wheel product.

8. The method of claim 1, wherein the substrate is made of a composite material.

9. The method of claim 8, wherein the composite material is selected from the group consisting of graphite, fiberglass and aramid.

10. The method of claim 1, wherein the clear coating layer is an acrylic clear coat.

11. The method of claim 1, wherein the clear coating layer is a polyester clear coat.

12. The method of claim 10, wherein the acrylic clear coating layer is applied to the surface of the substrate in powdered form.

13. The method of claim 11, wherein the polyester clear coating layer is applied to the surface of the substrate in powdered form.

14. The method of claim 3, wherein curing of the clear coating layer onto the surface of the substrate is at a temperature of about 350°

F. for about 30 minutes.

15. The method of claim 1, wherein the preceramic resin film is a polysiloxane composition.

16. The method of claim 1, wherein the preceramic resin film is a polysilazane composition.

17. The method of claim 3, wherein the preceramic resin film is applied to the cured clear coated surface of the substrate by spray application.

18. The method of claim 17, wherein the curing of the preceramic resin film onto the clear coated surface of the substrate is at a temperature of about 180°

F. for about four hours.

19. The method of claim 1, wherein the ceramic shell is about 3 microns to about 7 microns in thickness over the coated substrate.

20. The method of claim 1, wherein the ceramic shell is about 4 microns to about 6 microns in thickness over the coated substrate.

21. The method of claim 1, wherein the substrate has a paint layer.

22. A method for the surface coating of an aluminum alloy substrate, the method comprises:

applying a uniform clear coating layer to the surface of the aluminum alloy substrate; and

then applying a preceramic resin film to the coated aluminum alloy substrate,

wherein the preceramic resin film is uniformly applied and cured onto the coated aluminum alloy substrate so as to result in a ceramic shell of about 3 microns to about 12 microns in thickness over the coated aluminum alloy substrate.

23. The method of claim 22, wherein the surface of the aluminum alloy substrate is pretreated before the uniform clear coating layer is applied to the surface of the aluminum alloy substrate.

24. The method of claim 22, wherein after applying the uniform clear coating layer to the surface of the aluminum alloy substrate, the clear coating layer is then cured onto the surface of the aluminum alloy substrate.

25. The method of claim 22, wherein after applying the preceramic resin film to the coated aluminum alloy substrate, the clear coating and the preceramic resin film are simultaneously cured onto the surface of the aluminum alloy substrate.