Plasma coatings and method of making the same

• US 8,865,264 B2
• Filed: 06/13/2013
• Issued: 10/21/2014
• Est. Priority Date: 08/26/2008
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Haack, Larry P., Straccia, Ann Marie
• Primary Examiner(s): LIGHTFOOT, ELENA TSOY
• Application Number:
  US13/917,064
• Publication Number:
  US 20130280435A1
• Time in Patent Office: 495 Days
• Field of Search: 427/446, 427/447
• US Class Current: 427/446
• CPC Class Codes: B05D 1/02 performed by spraying
• CPC Class Codes: B05D 1/62 Plasma-deposition of organic layers plasma deposition in general C23C14/00, C23C16/00
• CPC Class Codes: C23C 4/134 Plasma spraying
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31663 As siloxane, silicone or silane

Abstract

A method of coating a substrate surface. The method includes plasma spraying a direct-spray component onto a substrate surface, and plasma spraying an over-spray component onto the substrate surface. The direct-spray and over-spray components form a plasma coating surface contacting at least a portion of the substrate surface.

Claims

1. A method comprising:

plasma direct-spraying through a nozzle adaptor exit region to form a direct-spray component onto a substrate;

plasma over-spraying through the nozzle adaptor exit region to form an over-spray component onto the substrate; and

placing a shield to block various portions of the nozzle adaptor exit region to form the direct- and/or over-spray component to form a plasma coating contacting at least a portion of the substrate.

2. The method of claim 1, wherein the direct-spray component includes a single bounded direct-spray region, and the over-spray component includes a single bounded over-spray region adjacent to the single bounded direct-spray region.

3. The method of claim 1, wherein the direct-spray component includes a single bounded direct-spray region, and the over-spray component includes first and second discrete over-spray subcomponents including first and second bounded over-spray regions adjacent to the single bounded direct-spray region.

4. The method of claim 3, wherein the first and second bounded over-spray regions are not adjacent to each other.

5. The method of claim 1, wherein each of the direct-spray and over-spray components has a different cross-linked polymer chemistry.

6. The method of claim 1, wherein the direct- and over-spraying steps are performed in a single pass to form the plasma coating.

17. The method of claim 1, wherein the exit region is a rectangular exit region.

18. The method of claim 1, wherein the shielding step includes blocking the exit region to substantially preclude flow of the direct- and/or over-spray in the exit region to form the direct- and/or over-spray component.

19. The method of claim 1, wherein the delivering step is performed before the shielding step.

20. The method of claim 1, wherein the shielding step includes shielding one or more subregions of the exit region.

7. A method comprising:

plasma direct-spraying through a nozzle adaptor exit region to form a direct-spray component onto a substrate; and

plasma over-spraying through the nozzle adaptor exit region to form an over-spray component onto the substrate; and

placing a shield to block various portions of the nozzle adaptor exit region to form the direct- and/or over-spray component to form a plasma coating contacting less than the entire substrate.

8. The method of claim 7, wherein the direct-spray component includes a single bounded direct-spray region, and the over-spray component includes a single bounded over-spray region adjacent to the single bounded direct-spray region.

9. The method of claim 7, wherein the direct-spray component included a single bounded direct-spray region, and the over-spray component includes first and second discrete over-spray subcomponents including first and second bounded over-spray regions adjacent to the single bounded direct-spray region.

10. The method of claim 9, wherein the first and second bounded over-spray regions are not adjacent to each other.

11. The method of claim 7, wherein each of the direct-spray and over-spray components has a different cross-linked polymer chemistry.

12. The method of claim 7, wherein the plasma direct-spraying and over-spraying steps are performed in a single pass to form the plasma coating.

13. A method comprising:

plasma direct-spraying through a nozzle adaptor exit region to form a direct-spray component onto a substrate;

plasma over-spraying through the nozzle adaptor exit region to form an over-spray component onto the substrate; and

placing a shield to block various portions of the nozzle adaptor exit region to form the direct- and/or over-spray component, each having a different cross-linked polymer chemistry.

14. The method of claim 13, wherein the direct-spray component includes a single bounded direct-spray region, and the over-spray component includes a single bounded over-spray region adjacent to the single bounded direct-spray region.

15. The method of claim 13, wherein the direct-spray component included a single bounded direct-spray region, and the over-spray component includes first and second discrete over-spray subcomponents including first and second bounded over-spray regions adjacent to the single bounded direct-spray region.

16. The method of claim 15, wherein the first and second bounded over-spray regions are not adjacent to each other.