Coated Metallic Substrates Plasma Treatment Corrosion
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Solution Overview
Problem
Existing coated metallic and non-metallic substrates face challenges with corrosion protection, adherence, and maintaining appearance, especially when subjected to mechanical damage, and achieving a high-quality, cost-effective production of matt or colored surfaces with improved corrosion resistance.
Innovation Solution
A method involving plasma treatment and vapor deposition/sputtering technology to apply metallic layers with specific thicknesses, combined with polysiloxane layers and organosilicon compounds, to create substrates with enhanced corrosion protection and appearance retention, including the use of transparent or translucent metallic layers for specific aesthetic effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional coating systems are used to achieve high-quality attractive appearance, then surface appearance is improved, but corrosion protection is compromised due to mechanical damage susceptibility
Solution Approach 1:
The patent applies a multilayer coating system combining different materials: a base coating layer providing appearance properties and a conversion coating layer providing corrosion protection. This composite structure allows each layer to specialize in its function, with the conversion coating forming a protective barrier that prevents corrosion even when the surface undergoes mechanical damage.
Solution Approach 2:
The patent utilizes plasma treatment to fundamentally change the surface parameters of the substrate before coating. This plasma treatment modifies the surface energy, roughness, and chemical composition, creating an optimized surface that enhances both coating adherence and corrosion resistance, thereby improving reliability without compromising appearance.
2Strength
If mechanical damage occurs on coated surfaces, then adherence is improved through better bonding, but corrosion protection is compromised due to infiltration and flaking
Solution Approach 1:
The conversion coating layer is applied specifically to counteract the harmful effects of mechanical damage. This layer is designed to prevent corrosion infiltration and flaking by forming a protective barrier that acts in advance against corrosive agents, thereby maintaining corrosion protection even when the surface experiences mechanical stress.
Solution Approach 2:
The multilayer structure with the conversion coating layer provides specialized corrosion protection that remains effective even when the base coating undergoes mechanical damage. The conversion coating's unique properties allow it to maintain integrity and prevent infiltration while the base coating provides appearance properties.
3Reliability
If plasma treatment and polysiloxane layers are applied to enhance corrosion protection and adherence, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functions into integrated layers: the conversion coating layer simultaneously provides corrosion protection, enhances adherence, and maintains surface appearance properties. This merging of functions reduces the need for separate treatment steps and simplifies the overall manufacturing process while maintaining high reliability.
Solution Approach 2:
Plasma treatment modifies surface parameters to optimize coating performance, and the conversion coating layer is designed to form specifically under these modified conditions. This approach ensures that the coating processes are streamlined and that the final product achieves high reliability without requiring overly complex manufacturing procedures.
4Illumination intensity
If transparent or translucent metallic layers are applied for aesthetic effects, then appearance is improved, but corrosion protection is reduced due to thinner layer coverage
Solution Approach 1:
The patent uses a composite coating system where a transparent or translucent metallic layer provides aesthetic appearance properties, while an underlying conversion coating layer provides comprehensive corrosion protection. This composite structure allows the thin metallic layer to maintain appearance quality while the conversion coating ensures adequate corrosion protection despite the reduced thickness of the metallic layer.
Solution Approach 2:
The conversion coating layer acts as an intermediary between the substrate and the thin metallic layer. This intermediary layer provides the necessary corrosion protection and adherence, allowing the thin metallic layer to focus on providing aesthetic effects without compromising corrosion protection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method provides substrates with excellent corrosion resistance, good adherence, and retention of matt or glossy appearances even after mechanical damage, enabling high-quality, cost-effective production suitable for mass production and various applications.
Implementation Method 1
plasma treatment with the plasma generator or corona treatment of the non-metallic substrate, in some cases plastic substrate, or of the coatable surface of the non-metallic substrate
Implementation Method 2
plasma treatment with the plasma generator or corona treatment of the non-metallic substrate
Implementation Method 3
treating of the non-metallic substrate, in some cases plastic substrate, obtained according to step a) or d), or of the coatable surface of the non-metallic substrate, in some cases plastic substrate, with at least one organosilicon compound, in some cases by way of plasma polymerization, thus forming a polysiloxane layer
Implementation Method 4
applying at least one metallic layer, containing or consisting of one first metal selected from the group consisting of aluminum, silver, gold, lead, vanadium, manganese, magnesium, iron, cobalt, nickel, copper, chromium, palladium, molybdenum, tungsten, platinum, titanium, zirconium and zinc, in some cases aluminum, or containing or consisting of a first metal alloy from the group consisting of brass, bronze, steel, in some cases stainless steel, aluminum, manganese and titanium alloys, with the application system, in some cases by way of vapor deposition and/or sputtering technology
Implementation Method 5
applying at least one metallic layer, containing or consisting of one first metal selected from the group consisting of aluminum, silver, gold, lead, vanadium, manganese, magnesium, iron, cobalt, nickel, copper, chromium, palladium, molybdenum, tungsten, platinum, titanium, zirconium and zinc, in some cases aluminum, or containing or consisting of a first metal alloy from the group consisting of brass, bronze, steel, in some cases stainless steel, aluminum, manganese and titanium alloys, with the application system, in some cases by way of vapor deposition and/or sputtering technology
Data Source
AI summary
The present disclosure relates to coated non-metallic substrates and coated metallic substrates, and methods for producing such coated substrates. A variant of the method is characterized in that a mat or glossy coating is underneath a metallic layer obtained in some cases by way of vapor deposition and/or sputtering. In another variant, the metallic is sufficiently thin so that it remains transparent or translucent to visible light. The coated substrates may include multiple layers such as metallic layers, polysiloxane layers, a color layer, a conversion layer, a primer layer, and/or a transparent or colored layer. An application system for applying a metallic layer to at least one surface of a substrate may include a plasma generator and/or a corona system for treating one or more layers by plasma treatment and/or corona treatment.