Multi-layer coating and method of applying the same to an implement body

Abstract

A multilayer coating and method of application onto the surface of an implement, such as a counterweight for use in industrial applications, composed of a substrate is provided. The method involves comprehensive surface preparation, including performing one or more cleaning procedures, followed by the application of a multilayer coating comprising an epoxy primer layer, a filler layer including a body filler material and at least one base primer coat, and a final primer coat. The final primer coat comprises at least one final primer coat layer, the at least one final primer coat layer comprising a polyurethane primer and acrylic polyurethane varnish. The final primer coat effectively seals the substrate, minimizing moisture penetration and reducing the risk of blister formation. The method ensures prolonged durability and aesthetic integrity, making it suitable for a wide range of industrial applications where substrates are exposed to harsh environmental conditions.

Description

MULTI-LAYER COATING AND METHOD OF APPLYING THE SAME TO AN IMPLEMENT BODYTECHNICAL FIELD

[0001] The present disclosure generally relates to coatings and surface treatments for metallic substrates, and more particularly to a method of application of a multilayer coating onto iron castings.BACKGROUND

[0002] In the construction industry, protective coatings applied to industrial or engineering machinery are vital for enhancing durability and aesthetic appeal. These coatings ensure that the equipment can withstand environmental challenges while maintaining an attractive appearance. These heavy-duty components are subjected to a range of environmental stressors, including temperature fluctuations during transit and exposure to winter weather conditions in storage yards.

[0003] For example, in applications such as counterweights for cranes, forklifts, excavators, draw bridges and the like, durability against harsh weather conditions in operation and in shipping and delivery is paramount. Despite maintenance efforts, coated counterweights frequently develop blisterlike deformities (local delamination of the coating) visible on the exterior surface, undermining its durability and aesthetic appeal. The blisters are formed due to temperature fluctuations inducing changes in the moisture content and properties of the counterweight substrate material, which leads to swelling in the body fdler layer between the substrate and the primed surface. As such, labor- intensive repair processes are necessary to remove the formed blisters. Common repair processes involve sanding the substrate to remove all traces of body filler and rust, followed by the reapplication of body filler and primer, before finishing with paint. These intermediate processes can be inefficient and costly.

[0004] As such, there is a need for a multilayer coating that has a reduced sensitivity to blistering. Furthermore, there is a need for a method of application for the multilayer coating to an implement body that prevents moisture penetration, thereby safeguarding against the formation of blisters and ensuring prolonged durability and aesthetic integrity of the heavy-duty component or iron casting.BRIEF SUMMARY OF THE INVENTION

[0005] The present disclosure is directed to a multilayer coating and method of applying the same to an implement formed of an oxidizable metallic substrate. The multilayer coating comprises an epoxy primer layer; a filler layer, the filler layer including a body filler material a base primer coat; and a final primer coat comprising at least one final primer coat layer comprising a blend of a polyurethane primer and an acrylic polyurethane varnish, wherein the polyurethane primer comprises from about 65% by weight to 75% by weight of the at least one final primer coat layer, and the acrylic polyurethane varnish comprises at least 25% by weight of the at least one final primer coat layer.

[0006] The present disclosure further provides a method of applying the multilayer coating to an implement body comprised of a substrate, the substrate having an interior surface and an exterior surface. The method may comprise the following steps: performing at least one cleaning procedure on at least one of the interior surface and the exterior surface; applying an epoxy primer layer to each of the interior surface and the exterior surface and allowing the epoxy primer layer to cure for a first predetermined curing duration; applying a filler layer to each of the interior surface of the substrate and the exterior surface of the substrate, wherein applying the filler layer to the substrate further comprises the steps of: applying a first application of a body filler material to at least a portion of the epoxy primer layer deposited on each of the interior surface of the substrate and the exterior surface of the substrate and allowing the first application of body filler material to dry for a predetermined drying duration; sanding the first application of body filler material when the material is in a dry state; and applying a first coat of a base primer to the first application of the body filler material deposited on each of the epoxy primer layer at each of the interior surface of the substrate and the exterior surface of the substrate and allowing the first coat of base primer to cure for a second predetermined curing duration; applying a final primer coat to each of the interior surface and the exterior surface of the substrate and allowing the final primer coat to cure for a third predetermined curing duration, wherein the finish primer coat comprises at least one final primer coat layer comprising a blend of a polyurethane primer and an acrylic polyurethane varnish.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the subject matter. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

[0008] FIG. 1 illustrates a flow diagram detailing the steps of the present method of application for the primer paint composition to a substrate.

[0009] FIG. 2 is a perspective view of an example implement, displayed as a counterweight for industrial applications, formed of an oxidizable metallic substrate material.

[0010] FIG. 3 is a cross-sectional view of the example implement of FIG. 2 taken along line 3-3 showing the application of the multilayer coating to the oxidizable metallic substrate.DETAILED DESCRIPTION OF THE INVENTION

[0011] While the present disclosure may be described with respect to specific applications or industries, those skilled in the art will recognize the broader applicability of the disclosure.

[0012] Those having ordinary skill in the art will recognize the terms such as “a”, “an”, “the”, “at least one”, and “one or more” are used interchangeably to indicate that at least one of the items is present. A plurality of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., of quantities or conditions) in this specification, unless otherwise indicated expressly or clearly in view of the context, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. In addition, a disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range.

[0013] The terms “comprising”, “including”, and “having” are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. Orders of steps, processes, and operations may be altered when possible, and additional or alternative steps may be employed. As used in this specification, the term “or” includes any one and all combinations of the associated listed items. The term “any of’ is understood to include any possible combination of referenced items, including “any one of’ the referenced items. The term “any of’ is understood to include any possible combination of referenced claims of the appended claims, including “any one of’ the referenced claims.

[0014] Features shown in one figure may be combined with, substituted for, or modified by, features shown in any of the figures. Unless stated otherwise, no features, elements, or limitations are mutually exclusive of any other features, elements, or limitations. Furthermore, no features, elements, or limitations are absolutely required for operation. Any specific configurations shown in the figures are illustrative only and the specific configurations shown are not limiting of the claims or the description.

[0015] For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. Those having ordinary skill in the art will recognize that terms such as “above”, “below”, “upward”, “downward”, “top”, “bottom”, etc., may be used descriptively relative to the figures, without representing limitations on the scope of the invention, as defined by the claims. Any numerical designations, such as “first” or “second” are illustrative only and are not intended to limit the scope of the disclosure in any way.

[0016] The following discussion and the accompanying figures disclose a multilayer coating and method of application onto the surface of a substrate material that forms an implement such as a counterweight for use in industrial applications. While the multilayer coating and method of application are illustrated and described herein on an oxidizable metallic substrate, particularly large iron castings such as counterweights applicable to industrial or construction machinery, it will be understood that the primer paint coating and associated method of application may be used on metallic substrates within a variety of applications where substrates are subjected to prolonged harsh environmental conditions and / or wherein the aesthetic appearance of the coated implement is valued, such as, but not limited to, the automotive, aerospace, or marine industries.

[0017] In a general sense, the multilayer coating and method of application aid in the reduction and / or elimination of blisters formed on the exterior surface of the coated substrate by preventing moisture from penetrating the body filler layer between the substrate and primed surface. A decrease in moisture penetration results in a reduction of blistering, leading to fewer necessary or required repairs. As a result, less downtime is needed for maintenance, as the coated substrate maintains its smooth and factory-like appearance for a longer duration.

[0018] More particularly, referring now to the drawings, FIG. 1 shows a flow diagram detailing the steps 101-106 of the present method 100 for application of the multilayer coating 13 to an implement comprised of an oxidizable metallic substrate. An example implement, namely acounterweight for use in industrial applications, comprising a body 10 that defines an interior surface 11 and an exterior surface 12, is shown in one example embodiment in FIG. 2.

[0019] Referring to FIG. 1, at step 101, an implement comprising a body 10 formed of a substrate material and having an interior surface 11 and an exterior surface 12 is provided and shown by example in FIG. 2. The substrate may be a metallic material, or more particularly, an oxidizable metallic material such as, but not limited to, an iron or steel material. The implement itself may be purposed for use as a workpiece or component of heavy machinery and / or industrial equipment. By one non-limiting example, the substrate may be an iron casting, such as a counterweight utilized in crane operations, forklifts, excavators, draw bridges or similar applications.

[0020] Next, at step 102, the substrate may undergo one or more cleaning procedures. The one or more cleaning procedures function to ensure that the implement body's 10 interior surface 11 and exterior surface 12 are thoroughly cleaned and substantially free of contaminants, dust, dirt, oil, grease, rust, scale, salt, old paint and / or coatings, and other surface contaminants and the like. Further, the one or more cleaning procedures may aid in polishing the surface of the substrate. The one or more cleaning procedures may include physical and / or chemical cleaning methods such as shotblasting, sandblasting, mechanical cleaning, chemical cleaning with cleaning agents or solvents, ultrasonic cleaning, electrolytic cleaning, and combinations thereof and the like. In one example, the implement body 10 is shotblasted, wherein an abrasive material is forcibly propelled at a high velocity onto the interior surface 11 and exterior surface 12 using compressed air and / or centrifugal force. After shotblasting, the implement body 10 may undergo additional physical or mechanical surface cleaning to remove any residual abrasive materials or debris that may remain from the shotblasting process.

[0021] At step 103, an epoxy primer layer 14 is applied to the interior surface 11 and the exterior surface 12 of the implement body 10 and subsequently allowed to cure for a first predetermined curing duration. The epoxy primer layer 14 may function to form a thin, protective layer that adheres strongly to the cleaned interior surface 11 and exterior surface 12 of the body 10 formed by the substrate, providing a suitable base for subsequent coating layers once cured. The epoxy primer layer 14 may be comprised of an epoxy resin, a curing agent or hardener, and a pigment. An example of a suitable epoxy primer is a 2K or two-component epoxy primer commercially available from most paint manufacturers.

[0022] The epoxy primer layer 14 may be applied using suitable means as known in the art, such as spraying, brushing, dipping, or roller coating. The epoxy primer layer 14 may be generated or formed having a substantially uniform thickness in a dry state of from about 60 m to about 80 pm. Once applied, the epoxy primer layer 14 may cure at ambient temperature, particularly from about 5°C to about 15°C for the first predetermined curing duration of from about 12 hours to about 24 hours.

[0023] Once cured, the epoxy primer layer 14 may undergo inspection to ensure uniform coverage, proper adhesion, and absence of any defects or imperfections. Inspection may involve visual examination, as well as testing for adhesion strength and coating thickness using appropriate tools and techniques known in the art. Any discrepancies or areas requiring attention are identified during inspection and repaired before proceeding with further application of additional layers of the multilayer coating 13.

[0024] Next, at step 104, a filler layer 16 is applied onto the epoxy primer layer 14, at each of the interior surface 11 and exterior surface 12 of the implement body 10. More particularly, step 104 comprises several sub-steps, namely sub-steps 104a-104d. The filler layer 16 may comprise a body filler material and at least one coat of a base primer. The body filler material may function to fill in any surface imperfections, such as dents, scratches, or irregularities of the substrate material, to create a smooth and uniform surface. Additionally, the body filler material may improve the implement body's 10 overall appearance.

[0025] The body filler material may comprise a resin, curing agent, and filler. Optionally, the body filler material may comprise one or more of a solvent and pigment. An example of a suitable body filler material includes, but is not limited to, those sold under the tradename Bondo® Filler & Resin, commercially available from 3M of St. Paul, Minnesota, USA. The body filler material may be applied by suitable methods known in the art such as by manual application. For example, a technician may manually deposit (using, e.g., a hand tool) an appropriate amount of body filler material for application onto the epoxy primer layer 14 at select locations of the interior surface 11 and exterior surface 12 of the implement body 10.

[0026] More particularly, at sub step 104a, a first application of the body filler material 18 is first applied onto at least a portion of the epoxy primer layer 14 at one or more predetermined locations on the interior surface 11 where surface imperfections, such as dents, scratches, or irregularities in the substrate are visible. Following the application, the first application of body filler material 18 isallowed to dry, cure, or harden for a predetermined drying duration, such that the resin of the body filler material begins to polymerize or cross-link in the presence of the curing agent. This chemical reaction causes the first application of body filler material 18 to harden and solidify, forming a durable bond with the epoxy primer layer 14. In one example, the predetermined drying duration is from about 2 hours to about 3 hours.

[0027] Once cured, the first application of body filler material 18 may be sanded to achieve a smooth and uniform finish. Subsequently, compressed air may be applied to the interior surface 11 of the implement body, such that any dust, debris, or loose particles from the application or sanding of the body filler material 18 are removed from the respective surfaces 11, 12.

[0028] Next, at sub step 104b, a first base primer coat 20 may be applied onto the first application of body filler material 18 and the epoxy primer layer 14 at the interior surface 11 of the implement body 10. The first base primer coat 20 serves as an additional protective layer, enhancing adhesion and providing a suitable surface for subsequent coating layers 22, 24, 26, 28.

[0029] The first base primer coat 20 may be comprised of a blend of a polyurethane primer and an acrylic polyurethane varnish. An example of a suitable polyurethane primer is sold under the tradename YGPU-8001 ACRYLIC POLYURETHANE VARNISH, commercially available from Beijing Yaguang Paint Co., LTD., of Beijing, China. In preferred embodiments, the first base primer coat 20 includes between about 60% and 80% by weight polyurethane primer, more preferably between about 65% and 75% by weight polyurethane primer, and even more preferably 70% by weight polyurethane primer.

[0030] An example of a suitable acrylic polyurethane varnish is sold under the tradename YGPU- 6000 POLYURETHANE PRIMER, commercially available from Beijing Yaguang Paint Co., LTD., of Beijing, China. In preferred embodiments, the first base primer coat 20 includes between about 20% and 40% by weight acrylic polyurethane varnish, more preferably between about 25% and 35% by weight acrylic polyurethane primer, and even more preferably 30% by weight acrylic polyurethane varnish.

[0031] Blending of the first base primer coat components can be accomplished according to a variety of new or known blending techniques. For example, the polyurethane primer and acrylic polyurethane varnish of the first base primer coat 20 may be combined in a blender, such as a large bin or other container, or deposited in a mixing machine at the desired percentages. The container ormixing machine can be used to intermix the components by rotation or stirring, (e.g., either manually by hand or utilizing a power mixer), to achieve a homogenous composition.

[0032] The first base primer coat 20 may be applied using various methods such as spraying, brushing, dipping, or roller coating. The first base primer coat 20 may be generated or formed having a substantially uniform thickness in a dry state of from about 60 pm to about 80 pm. Once applied, the first base primer coat 20 may cure at ambient temperature, particularly from about 5°C to about 15°C for a second predetermined curing duration of from about 6 hours to about 8 hours.

[0033] Accordingly, once imperfections are remedied and the interior surface 11 of the implement body 10 is primed via sub steps 104a and 104b, the respective interior surface 11 may undergo inspection to ensure uniform primer coverage, proper body filler and base primer adhesion, as well as the absence of any additional imperfections. Inspection may involve visual examination. Any discrepancies or areas requiring attention are identified during inspection and repaired through additional rounds of body filler applications (sub step 104a) and base primer coatings (sub step 104b) to the interior surface 11, before proceeding with the filling and priming of the exterior surface 12 of the substrate, as described at sub steps 104c and 104d.

[0034] For example, it is contemplated that the interior surface 11 of the implement body 10 may undergo additional rounds of body filler application, followed by base primer coatings, as described in sub steps 104a and 104b, to achieve complete coverage of any imperfections. As such, it is contemplated that the filler layer 16 may be comprised of a first application of the body filler material 18 to the interior surface 11 followed by a first base primer coat 20 to the interior surface 11. After inspection, if additional imperfections are located, a second touch-up application of the body filler material 22 to the interior surface 11 may be necessary. Said another way, sub-steps 104a and 104b may be repeated such that, for example, a second application of the body filler material 22 is applied to the first base primer coat 20 at the interior surface 11 of implement body 10 and allowed to dry for the predetermined drying duration.

[0035] Once cured, the second application of body filler material 22 may be sanded to achieve a smooth and uniform finish. Subsequently, compressed air may be applied to the interior surface 11 of the implement body 10, such that any dust, debris, or loose particles from the application or sanding of the body filler material are removed from the respective surfaces 11, 12.

[0036] Next, at sub steps 104c and 104d, the body filler material and at least one coat of base primer are applied to the epoxy primer layer 14 of the exterior surface 12 of the implement body 10in like manner as described herein for the interior surface 11 of the implement body 10. More particularly, as illustrated in sub step 104c, a first application of the body filler material 18 is applied onto at least a portion of the epoxy primer layer 14 at one or more predetermined locations on the exterior surface 12 where surface imperfections, such as dents, scratches, or irregularities in the substrate are visible. Following application, the first application of the body filler material 18 is allowed to dry, cure, or harden such that the resin of the body filler material begins to polymerize or cross-link in the presence of the curing agent. This chemical reaction causes the first application of the body filler material 18 to harden and solidify, forming a durable bond with the epoxy primer layer 14. In one example, the predetermined drying duration is from about 2 hours to about 3 hours.

[0037] Once cured, the first application of the body filler material 18 may be sanded to achieve a smooth and uniform finish. Subsequently, compressed air is applied to the exterior surface 12 of the implement body 10, such that any dust, debris, or loose particles from the application of the body filler material are removed from the respective surfaces 11,12.

[0038] Thereafter, at sub step 104d, a first base primer coat 20 may be applied onto the first application of the body filler material 18 and the epoxy primer layer 14 at the exterior surface 12 of the implement body 10. The first base primer coat 20 serves as an additional protective layer, enhancing adhesion and providing a suitable surface for subsequent coating layers 22, 24, 26, 28. The first base primer coat 20 may be applied using various methods such as spraying, brushing, dipping, or roller coating. The first base primer coat 20 may be generated or formed having a substantially uniform thickness in a dry state of from about 60 pm to about 80pm. Once applied, the first base primer coat 20 may cure at ambient temperature, particularly from about 5°C to about 15°C for a second predetermined curing duration of from about 6 hours to about 8 hours.

[0039] Once surface imperfections, such as dents, scratches, or irregularities in the substrate are remedied on the exterior surface 12 of the implement body 10, the substrate is adequately primed. Accordingly, once primed via sub steps 104c and 104d, the respective exterior surface 12 may undergo inspection to ensure uniform base primer coverage, proper body filler and base primer adhesion, as well as the absence of any additional imperfections. Inspection may involve visual examination. Any discrepancies or areas requiring attention are identified during inspection and repaired through additional rounds of body filler applications (sub step 104c) and base primer coatings (sub step 104d) to the exterior surface 12, before proceeding with the next step, step 105.

[0040] For example, it is contemplated that the exterior surface 12 of the implement body 10 may undergo additional rounds of body filler application, followed by base primer coatings, as described in sub steps 104c and 104d, to achieve complete coverage of any imperfections. As such, it is contemplated that the filler layer 16 may be comprised of a first application of the body filler material 18 to the exterior surface 12 followed by a first base primer coat 20 to the exterior surface 12. After inspection, if additional imperfections are located, a second touch-up application of the body filler material 22 to the exterior surface 12 followed by a second base primer coat 24 to the exterior surface 12 of the implement body 10 may be necessary. Said another way, sub-steps 104c and 104d may be repeated such that, for example, a second application of the body filler material 22 is applied to the first base primer coat 20 at the exterior surface 12 of implement body 10 and allowed to dry for the predetemiined drying duration.

[0041] Once cured, the second application of body filler material 22 may be sanded to achieve a smooth and uniform finish. Subsequently, compressed air may be applied to the exterior surface 12 of the implement body 10, such that any dust, debris, or loose particles from the application or sanding of the body filler material are removed from the respective surfaces 11, 12.

[0042] A second base primer coat 24 may be applied onto the second touch up application of body filler material 22 and the first base primer 20 of the exterior surface 12 of the implement body 10. The second base primer coat 24 serves as an additional protective layer, enhancing adhesion and providing a suitable surface for subsequent coating layers 26,28.

[0043] Next, at step 105, a final primer coat 25 is applied onto the filler layer 16 of the interior surface 11 and exterior surface 12 of the implement body 10. The final primer coat 25 may comprise at least one final primer coat layer. In preferred embodiments, the final primer coat 25 may comprise a first final primer coat layer 26 and a second final primer coat layer 28. The final primer coat 25 functions to impart weatherproof properties to the interior surface 11 and exterior surface 12 of the implement body 10. As such, the final primer coat 25 may reduce and / or prevent moisture penetration from the substrate into the first and second applications of the body filler material 18, 22 such that body fillers layers 18, 22 are properly sealed between the epoxy primer layer 14 and the final primer coat 25. Prevention and / or reduction of moisture penetration results in a reduction and / or elimination of blister formation on the surface of the substrate.

[0044] The first and second final primer coat layers 26, 28 of the final primer coat 25 may be composed of a blend of a polyurethane primer and an acrylic polyurethane varnish. An example of asuitable polyurethane primer is sold under the tradename YGPU-8001 ACRYLIC POLYURETHANE VARNISH, commercially available from Beijing Yaguang Paint Co., LTD., of Beijing, China. In preferred embodiments, the first and second final primer coat layers 26, 28 include between about 60% and 80% by weight polyurethane primer, more preferably between about 65% and 75% by weight polyurethane primer, and even more preferably 70% by weight polyurethane primer.

[0045] An example of a suitable acrylic polyurethane varnish is sold under the tradename YGPU- 6000 POLYURETHANE PRIMER, commercially available from Beijing Yaguang Paint Co., LTD., of Beijing, China. In preferred embodiments, the first and second final primer coat layers 26, 28 include between about 20% and 40% by weight acrylic polyurethane varnish, more preferably between about 25% and 35% by weight acrylic polyurethane primer, and even more preferably 30% by weight acrylic polyurethane varnish.

[0046] Blending of the final primer coat components can be accomplished according to a variety of new or known blending techniques. F or example, the polyurethane primer and acrylic polyurethane varnish of the first and second final primer coat layers 26, 28 may be combined in a blender, such as a large bin or other container, or deposited in a mixing machine at the desired percentages. The container or mixing machine can be used to intermix the components by rotation or stirring, (e.g., either manually by hand or utilizing a power mixer), to achieve a homogenous composition.

[0047] The final primer coat 25 may be applied using suitable means as known in the art, such as spraying, brushing, dipping, or roller coating. The final primer coat 25 may be generated or formed having a substantially uniform thickness in a wet state of from about 120 pm to about 160 pm. It is contemplated that if multiple final primer coat layers 26, 28 are applied to the interior surface 11 and exterior surface 12 of the implement body 10, such as two final primer coat layers 26, 28, a wet-on- wet application method may be utilized. This method involves applying the second final primer coat layer 28 while the first final primer coat layer 26 is still wet, with a flash-off duration allowed between each coat of from about 15 minutes to 30 minutes, allowing for simultaneous drying of both coating layers 26, 28.

[0048] Lastly, at step 106, the final primer coat 25 is allowed to sufficiently dry or cure for a third predetermined curing duration. The third predetermined curing duration may be a period of about 24 hours at ambient temperature, prior to shipment to a consumer.

[0049] It is also contemplated that the primed implement may optionally receive at least one layer of a finishing paint and / or varnish before shipment to a consumer. The finishing paint and / or varnish may function to provide an aesthetically pleasing finish to the implement, create a sealed surface further resistant to water penetration, provide additional resistance to scratches or abrasions, or prevent fading or discoloration. The finishing paint and / or varnish may be applied to the final primer coat 25 at each of the interior surface 11 and exterior surface 12 of the substrate. The finishing paint and / or varnish may be allowed to sufficiently dry for a predetermined period of about 24 hours to 28 hours, prior to shipment to a customer.

[0050] In the manner described above, the multilayer coating 13 and corresponding method of application 100 in the present teaching provides substrates with a smooth and factory-like appearance. Moreover, the multilayer coating 13 and method of application 100 minimizes the potential for blistering, by effectively sealing the substrate and providing improved adhesion between layers 14, 16, 18, 20, 22, 24, 26, 28, thereby maintaining the integrity of the interior surface 11 and exterior surface 12 of the implement even under harsh environmental conditions.

[0051] With regard to the processes, systems, methods, etc. described herein, it should be understood that, although the steps of such processes, etc. have been described as occurring according to a certain ordered sequence, such processes could be practiced with the described steps performed in an order other than the order described herein. It further should be understood that certain steps could be performed simultaneously, that other steps could be added, or that certain steps described herein could be omitted. In other words, the descriptions of processes herein are provided for the purpose of illustrating certain embodiments and should in no way be construed so as to limit the claimed invention.

[0052] The detailed description and the drawings or figures are supportive and descriptive of the present teachings, but the scope of the present teachings is defined solely by the claims. While some of the best modes and other embodiments for carrying out the present teachings have been described in detail, various alternative designs and embodiments exist for practicing the present teachings defined in the appended claims.

[0053] While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Any feature of any embodiment may be used in combination with or substituted for any other featureor element in any other embodiment unless specifically restricted. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

[0054] Benefits, other advantages, and solutions to problems, and any element or elements that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as critical, required, or essential features or elements of any or all of the claims, unless such benefits, advantages, solutions, or elements are expressly stated in such claims.

[0055] LISTING OF REFERENCE NUMERALS

[0056] 10 Implement Body

[0057] 11 Interior Surface

[0058] 12 Exterior Surface

[0059] 13 Multilayer Coating

[0060] 14 Epoxy Primer Layer

[0061] 16 Filler Layer

[0062] 18 Body Filler Material

[0063] 20 First Base Primer

[0064] 22 Second Application of Touch-up Body Filler Material

[0065] 24 Second Base Primer

[0066] 25 Final Primer Coat

[0067] 26 First Final Primer Coat Layer

[0068] 28 Second Final Primer Coat Layer

[0069] 100 Method of Application

Claims

CLAIMSWhat is claimed is:

1. A method of applying a multilayer coating to an implement body comprised of a substrate, the implement body defining an interior surface and an exterior surface, the method comprising the steps of: performing at least one cleaning procedure on at least one of the interior surface and the exterior surface; applying an epoxy primer layer to each of the interior surface and the exterior surface and allowing the epoxy primer layer to cure for a first predetermined curing duration; applying a filler layer to each of the interior surface of the substrate and the exterior surface of the substrate, wherein applying the filler layer to the substrate further comprises the steps of: applying a first application of a body filler material to at least a portion of the epoxy primer layer deposited on each of the interior surface of the substrate and the exterior surface of the substrate and allowing the first application of body filler material to dry for a predetermined drying duration; sanding the first application of body filler material when the material is in a dry state; and applying a first base primer coat to the first application of the body filler material deposited on the epoxy primer layer at each of the interior surface of the substrate and the exterior surface of the substrate and allowing the first base primer coat to cure for a second predetermined curing duration; and applying a final primer coat to each of the interior surface and the exterior surface of the substrate and allowing the final primer coat to cure for a third predetermined curing duration, wherein the final primer coat comprises at least one final primer coat layer, the at least one final primer coat layer comprising a blend of a polyurethane primer and an acrylic polyurethane varnish.

2. The method of claim 1, wherein the polyurethane primer comprises from about 65% by weight to about 75% by weight of the at least one final primer coat layer, and the acrylic polyurethane varnish comprises at least 25% by weight of the at least one final primer coat layer.

3. The method of claim 2 wherein the substrate is an oxidizable metallic material.

4. The method of claim 3 wherein the substrate is a cast iron material.

5. The method of claim 4 wherein the step of performing at least one cleaning procedure on at least one of the interior surface of the substrate and the exterior surface of the substrate further comprises at least one of one of shotblasting, sandblasting, mechanical cleaning, chemical cleaning, ultrasonic cleaning, or electrolytic cleaning.

6. The method of claim 5 wherein the step of performing at least one cleaning procedure on at least one of the interior surface of the substrate and the exterior surface of the substrate further comprises the steps of: shotblasting the exterior surface of the substrate; and mechanically cleaning the exterior surface of the substrate.

7. The method of claim 6 wherein the step of applying the epoxy primer layer to each of the interior surface of the substrate and the exterior surface of the substrate further comprises applying the epoxy primer via one of spraying, brushing, dipping, and roller coating.

8. The method of claim 7 wherein the epoxy primer layer has a thickness of from about 60 pm to about 80 pm in a dry state.

9. The method of claim 8 wherein applying the filler layer to the substrate further comprises the steps of: applying a second application of the body filler material to the first base primer coat at the exterior surface of the substrate and allowing the second application of body filler material to dry for a predetermined drying duration;sanding the first application of body filler material when the material is in a dry state; and applying a second base primer coat to the second application of body filler material at the exterior surface of the substrate.

10. The method of claim 9 wherein the filler layer has a thickness of from about 60 pm to about 80 pm in a dry state.

11. The method of claim 10 wherein the first base primer coat and second base primer coat have the same composition.

12. The method of claim 11 wherein applying the final primer coat to each of the interior surface and the exterior surface of the substrate further comprises: applying a first final primer coat layer to the first base primer coat deposited on the first application of the body filler material at the interior surface of the substrate; applying the first final primer coat layer to the second base primer coat deposited on the second application of body filler material at the exterior surface of the substrate, and allowing the first final primer coat layer to cure for the third predetermined curing duration; applying a second final primer coat layer to the first final primer coat layer deposited at each of the interior surface of the substrate and the exterior surface of the substrate; and allowing the final primer coat to cure for the third predetermined curing duration.

13. The method of claim 12, further comprising: applying at least one coat of finishing paint to the second final primer coat layer deposited at each of the interior surface of the substrate and the exterior surface of the substrate and allowing the at least one coat of finishing paint to dry for a predetermined drying duration.

14. The method of claim 12, wherein the first base primer coat, second base primer coat, first final primer coat layer and second final primer coat layer each have the same composition.

15. An implement composed of a substrate comprising: a body defining an interior surface and an exterior surface;a multilayer coating applied to each of the interior surface and exterior surface of the body, the multilayer coating comprising: an epoxy primer layer; a filler layer, the filler layer including: a body filler material; and a base primer coat; and a final primer coat having at least one final primer coat layer, the at least one final primer coat layer comprising a blend of a polyurethane primer and an acrylic polyurethane varnish, wherein the polyurethane primer comprises from about 65% by weight to 75% by weight of the at least one final primer coat layer, and the acrylic polyurethane varnish comprises at least 25% by weight of the at least one final primer coat layer.

16. The implement of claim 15, wherein the at least one final primer coat layer further comprises: a first final primer coat layer; and a second final primer coat layer deposited on the first final primer coat layer.

17. The implement of claim 16 wherein the substrate is an oxidizable metallic material.

18. The implement of claim 17 wherein the substrate is cast iron.

19. The implement of claim 18 wherein the epoxy primer layer has a thickness of from about60 pm to about 80 pm in a dry state.

20. The implement of claim 19 wherein the final primer coat has a thickness from about 120 pm to about 160 pm in a wet state.

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