Coated articles and methods of making the same

Patent metadata

Field	Value
Publication number	US-2016348248-A1
Application number	US-201615152311-A
Country	US
Kind code	A1
Filing date	May 11, 2016
Priority date	May 28, 2015
Publication date	Dec 1, 2016
Grant date	—

Abstract

During an example coating method, a metallic substrate is provided. A foundation coat precursor is applied on the metallic substrate. The foundation coat precursor includes a matrix and a plurality of capsules present in the matrix. Each capsule includes a shell and a healing agent surrounded by the shell. A basecoat precursor is applied, and a clearcoat precursor is applied. The metallic substrate, the foundation coat precursor, the basecoat precursor, and the clearcoat precursor are heated i) after each respective application or ii) simultaneously, in order to cure the foundation coat, basecoat, and clearcoat precursors and respectively form a foundation coat, a basecoat, and a clearcoat. The foundation coat is ultraviolet (UV) stable and bonds the metallic substrate to the basecoat and the clearcoat.

First claim

What is claimed is:

1 . A coating method, comprising:
providing a metallic substrate; applying a foundation coat precursor on the metallic substrate, the foundation coat precursor including:
a matrix; and
a plurality of capsules present in the matrix, each capsule including a shell and a healing agent surrounded by the shell;
applying a basecoat precursor; applying a clearcoat precursor; and heating the metallic substrate, the foundation coat precursor, the basecoat precursor, and the clearcoat precursor i) after each respective application or ii) simultaneously, in order to cure the foundation coat, basecoat, and clearcoat precursors and respectively form a foundation coat, a basecoat, and a clearcoat; wherein the foundation coat is ultraviolet (UV) stable and bonds the metallic substrate to the basecoat and the clearcoat.

2 . The method as defined in claim 1 wherein the plurality of capsules includes a blend of first and second capsules, wherein the first capsules include a resin as a first healing agent, and where the second capsules include a curing agent of the resin as a second healing agent.

3 . The method as defined in claim 1 wherein the healing agent is selected from the group consisting of silicone based polymers, polyurethane polymers, and alcohol-based sol-gel materials with nanoparticles therein.

4 . The method as defined in claim 1 wherein the matrix is a sol with silica nanoparticles suspended therein.

5 . The method as defined in claim 4 wherein the sol is an alcohol based sol.

6 . The method as defined in claim 1 wherein the shell of the capsule is a material that is capable of cross-linking with a silica nanoparticle in the matrix.

7 . The method as defined in claim 1 wherein the metallic substrate is not subjected to an electro-deposition (ELPO) operation.

8 . The method as defined in claim 1 wherein:
the applying of the foundation coat precursor includes dipping the metallic substrate in a tank containing the foundation coat precursor;
the applying of the basecoat includes spraying the basecoat over the foundation coat precursor after the foundation coat precursor has been applied on the metallic substrate; and
the applying of the clearcoat precursor includes spraying the clearcoat precursor over the basecoat precursor after the basecoat precursor has been applied over the foundation coat precursor.

9 . The method as defined in claim 1 wherein the heating of the metallic substrate includes positioning the metallic substrate in an oven after applying the foundation coat precursor, the basecoat precursor, and the clearcoat precursor, and heating the metallic substrate using the oven.

10 . A coated article, comprising:
a metallic substrate; a foundation coat bonded to the metallic substrate, the foundation coat including:
cross-linked silica particles; and
a plurality of capsules, each capsule including a shell and a healing agent surrounded by the shell, wherein the shell is chemically compatible with the cross-linked silica particles;
a basecoat disposed over the foundation coat, wherein the foundation coat is disposed between the metallic substrate and the basecoat; and a clearcoat disposed over the basecoat, wherein the basecoat is disposed between the clearcoat and the foundation coat.

11 . The coated article as defined in claim 10 wherein the coated article does not include an electro-deposition coat.

12 . The coated article as defined in claim 10 wherein the plurality of capsules includes a blend of first and second capsules, wherein the first capsules include a resin as a first healing agent, and where the second capsules include a curing agent of the resin as a second healing agent.

13 . The coated article as defined in claim 10 wherein the healing agent is selected from the group consisting of silicone based polymers, polyurethane polymers, and alcohol-based sol-gel materials with nanoparticles therein.

14 . The coated article as defined in claim 10 wherein the shell is selected from the group consisting of titania, silicon dioxide, quartz crystal, and silica glass.

15 . The coated article as defined in claim 10 wherein the metallic substrate is formed of steel, aluminum, or magnesium.

16 . A method for enhancing corrosion resistance of a metallic substrate, the method comprising:
incorporating a plurality of capsules in a matrix of a foundation coat precursor, each capsule including a shell and a healing agent surrounded by the shell; dipping the metallic substrate in a tank containing the foundation coat precursor in order to apply the foundation coat precursor over the metallic substrate; applying a basecoat precursor; applying a clearcoat precursor; and heating the metallic substrate, the foundation coat precursor, the basecoat precursor, and the clearcoat precursor i) after each respective application or ii) simultaneously, in order to cure the foundation coat precursor, the basecoat precursor, and the clearcoat precursor and to respectively form a foundation coat, a basecoat, and a clearcoat; wherein the healing agent, when released from the shell, adheres to at least one component of the foundation coat.

17 . The method as defined in claim 16 wherein the incorporating of the plurality of capsules in the matrix includes adding the capsules to the matrix in an amount ranging from about 1 wt % to about 40 wt % of a total wt % of the matrix.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Fan Hua-Tzu
• Arinez Jorge F
• Plazas Torres Alejandro Hernan

Classifications

• C23C26/00 Primary

  Coating not provided for in groups C23C2/00 - C23C24/00 · CPC title

• B05D7/14 Primary

  to metal, e.g. car bodies (involving a chemical reaction between the metal and the coating C23) · CPC title

• B05D2350/63

  ceramic layer · CPC title

• B05D7/24

  for applying particular liquids or other fluent materials · CPC title

• C09D175/04

  Polyurethanes · CPC title