Abstract: A hem flange treatment method. The method includes air plasma direct spraying a hem flange at an outer edge of an outer panel thereof with a plasma polymer direct spray to cover the outer edge with a protective direct spray region. The method further includes air plasma overspraying an inner cut edge of an inner panel of the hem flange with a plasma polymer overspray to form a protective overspray region that covers the inner cut edge.

Abstract: A plasma vapor deposited (PVD) coating method. The method includes overlaying a primer polymer layer onto a substrate surface. The method further includes overlaying a chrome metallic layer onto the primer polymer. The method also includes depositing a plasma vapor deposited (PVD) oxide layer of a thickness of 1 to 5 nanometers onto the chrome metallic layer and having a parameter of color change of the underlying chrome metallic layer. The color change may be determined according to the following equation: ?E*ab=?{square root over ((?L*)2+(?a*)2+(?b*)2)} L is the color brightness of the oxide layer, and a and b are the color-component dimensions of the oxide and metallic layers. ?E*ab may be less than 2.3. The method further includes overlaying an exposed polymeric layer onto the PVD oxide layer to form a protective layer at the interface between the exposed polymeric layer and the oxide layer.

Abstract: A plasma vapor deposited (PVD) coating method. The method includes overlaying a primer polymer layer onto a substrate surface. The method further includes overlaying a chrome metallic layer onto the primer polymer. The method also includes depositing a plasma vapor deposited (PVD) oxide layer of a thickness of 1 to 5 nanometers onto the chrome metallic layer and having a parameter of color change of the underlying chrome metallic layer. The color change may be determined according to the following equation: ?E*ab=?{square root over ((?L*)2+(?a*)2+(?b*)2)} L is the color brightness of the oxide layer, and a and b are the color-component dimensions of the oxide and metallic layers. ?E*ab may be less than 2.3. The method further includes overlaying an exposed polymeric layer onto the PVD oxide layer to form a protective layer at the interface between the exposed polymeric layer and the oxide layer.

Abstract: An article is disclosed that includes a metallic layer overlaying a substrate surface; a plasma vapor deposited (PVD) oxide layer overlaying the metallic layer; and an exposed polymeric layer overlaying the oxide layer to form a protective layer at the interface between the exposed polymeric layer and the oxide layer.

Abstract: A structural polymer insert. The insert includes a substrate having a surface and an adhesive with the substrate being an admixture of a polypropylene component and a glass fiber component. The surface has a plurality of oxygen atoms, optionally introduced by air plasma, in an amount of 1 to 60 atomic percent of all the atoms present on the surface. The foam adhesive is attached to the surface through one or more reactive moieties resulted from oxidative action of the oxygen atoms.

Abstract: A structural polymer insert. The insert includes a substrate having a surface and an adhesive with the substrate being an admixture of a polypropylene component and a glass fiber component. The surface has a plurality of oxygen atoms, optionally introduced by air plasma, in an amount of 1 to 60 atomic percent of all the atoms present on the surface. The foam adhesive is attached to the surface through one or more reactive moieties resulted from oxidative action of the oxygen atoms.

Abstract: A treated hem flange is disclosed. The treated hem flange includes an outer panel and an inner panel including first and second opposing surfaces terminating at a cut edge. The inner panel is positioned within the outer panel. The treated hem flange also includes an electrocoat applied to the inner panel surfaces and the cut edge to form inner panel coated regions and inner panel exposed regions. The treated hem flange also includes a plasma polymer coat applied to the inner panel exposed regions to form a barrier coating.

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.

Abstract: A coated metallic part includes a substrate including a metallic surface; a first coating layer supported on the metallic surface and including a first polymer, the first polymer including silicon; and a second coating layer including a second polymer different from the first polymer, the first coating layer being positioned between the metallic surface and the first coating layer. The first coating layer may have a silicon atomic percentage of 5 to 50 atomic weight percent. The first polymer of the first coating layer may have an oxygen-to-silicon ratio of 1.0 to 4.0. The second polymer of the second polymer layer may include at least one of an acrylic polymer, a polyester, an alkyd, a polyurethane, a polyamide, a polyether, a copolymer thereof, and a mixture thereof.

Abstract: An article is disclosed that includes a metallic layer overlaying a substrate surface; a plasma vapor deposited (PVD) oxide layer overlaying the metallic layer; and an exposed polymeric layer overlaying the oxide layer to form a protective layer at the interface between the exposed polymeric layer and the oxide layer.

Abstract: The present invention provides a method of increasing the surface energy of an article having a polymeric surface increasing the relative amount of nitrogen atoms or oxygen atoms within a portion of the surface to form a nitrogen or oxygen enriched surface layer. The method of the invention is advantageously applied to a vehicle body frame to facilitate adhesion of a windshield. In another embodiment of the invention a method for inhibiting sealer redeposition is provided in which a plastic component in an automobile is treated prior to being subjected to the various paint preprocessing baths.

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.

Abstract: According to at least one aspect of the present invention, a method is provided for forming a polymerized coating on a surface of a substrate. In at least one embodiment, the method comprises providing a plasma gun having an outlet; introducing a pre-polymer molecule into the outlet of the plasma gun to form a number of fragments of the pre-polymer molecule as a plasma output including a direct-spray component and an over-spray component; at least partially isolating the direct-spray component and the over-spray component from each other to respectively obtain an isolated directed-spray component and an isolated over-spray component; and depositing at least a portion of the isolated direct-spray component and the isolated over-spray component onto the surface of the substrate through the outlet to form a base polymerized coating. The plasma gun is optionally operated at atmospheric pressure.

Abstract: According to at least one aspect of the present invention, a method is provided for forming a polymerized coating on a surface of a substrate. In at least one embodiment, the method comprises providing a plasma gun having an outlet; introducing a pre-polymer molecule into the outlet of the plasma gun to form a number of fragments of the pre-polymer molecule as a plasma output including a direct-spray component and an over-spray component; at least partially isolating the direct-spray component and the over-spray component from each other to respectively obtain an isolated directed-spray component and an isolated over-spray component; and depositing at least a portion of the isolated direct-spray component and the isolated over-spray component onto the surface of the substrate through the outlet to form a base polymerized coating. The plasma gun is optionally operated at atmospheric pressure.

Abstract: In one embodiment, an article includes a surface; a metallic layer including a first metal and contacting the surface; and an oxide layer including an oxide of a second metal different from the first metal and contacting the metallic layer. The article may further include a polymer layer contacting the surface of the oxide layer directed away from the article surface. In certain instances, the article is a vehicle wheel.

Abstract: A system is provided for plasma treating a plastic component having an exterior surface and an inside surface. The system comprises at least one fixture. The fixture includes a support structure, a plurality of locating features, and a plurality of holding devices which cooperate to position a portion of the exterior surface to within a specified tolerance. The system further comprises at least one APAP nozzle configured to move relative to the exterior surface along a path, wherein the APAP nozzle directs a plasma jet onto the portion producing a functionalized polymer layer covering the portion.

Abstract: A surface treatment for polymeric part adhesion and a treated part is provided. In one aspect, a method for adhesively securing a part to a polymeric substrate is provided comprising providing an adhesive layer having a bonding surface having a first oxygen composition, a part having a bondable surface, and a polymeric substrate having a mating surface. Spray from an air plasma device is directed onto at least a portion of the bonding surface of the adhesive to provide a second oxygen composition on the bonding surface of the adhesive layer, with the second oxygen composition being greater than the first oxygen composition. The adhesive layer is secured between the bondable surface of the part and the mating surface of the polymeric substrate.

Abstract: According to at least one aspect of the present invention, a method is provided for forming a polymerized coating on a surface of a substrate. In at least one embodiment, the method comprises providing a plasma gun having an outlet; introducing a pre-polymer molecule into the outlet of the plasma gun to form a number of fragments of the pre-polymer molecule as a plasma output including a direct-spray component and an over-spray component; at least partially isolating the direct-spray component and the over-spray component from each other to respectively obtain an isolated directed-spray component and an isolated over-spray component; and depositing at least a portion of the isolated direct-spray component and the isolated over-spray component onto the surface of the substrate through the outlet to form a base polymerized coating. The plasma gun is optionally operated at atmospheric pressure.

Abstract: A structural polymer insert. The insert includes a substrate having a surface and an adhesive with the substrate being an admixture of a polypropylene component and a glass fiber component. The surface has a plurality of oxygen atoms, optionally introduced by air plasma, in an amount of 1 to 60 atomic percent of all the atoms present on the surface. The foam adhesive is attached to the surface through one or more reactive moieties resulted from oxidative action of the oxygen atoms.

Abstract: A method is provided for decorating a plastic component having an exterior surface with an initial surface energy. At least a portion of the exterior surface is decorated with a coating. The method comprises fixturing the plastic component. At least the portion of the exterior surface is positioned substantially within a specified tolerance. Plasma treating at least the portion to a treated surface energy greater than the initial surface energy with an atmospheric-pressure air plasma nozzle. Applying the coating to at least the portion of the exterior surface, wherein the coating has a coating surface energy that does not substantially exceed the treated surface energy. The coating is then cured.