Abstract: In an embodiment an apparatus for coating a substrate comprises: an array of plasma arcs; a first plurality of reagent manifolds located upstream of the array of plasma arcs and a second plurality of reagent manifolds located downstream of the array of plasma arcs, each manifold having at least one orifice through which a reagent is ejected into a plasma jet issuing from a respective plasma arc; and a controller which modulates the flow of reagent to each manifold according to the contours of the substrate and to the substrate position relative to the plasma arcs and the manifolds.

Abstract: A plastic panel assembly having a permanent mark therein at a subsurface location and formed after substantial manufacture of the panel assembly. The plastic panel includes a substrate and a coating over the substrate, the coating including a surface that defines an exterior surface of the panel assembly. A mark is located beneath the exterior surface of the panel assembly. In making the panel assembly, a plastic substrate is provided and a protective coating is applied to the substrate. After the step of applying the protective coating, a subsurface portion of panel assembly is exposed to a laser light. The laser light opacifies a subsurface portion of the panel assembly, thereby rendering the mark within the panel assembly.

Abstract: A plasma coating system includes at least one coating station with a first side and a second side defining a pathway with at least one bend. The coating station also includes a first plasma arc that provides a plasma jet directed towards a substrate. The first plasma arc is positioned on either the first side or the second side of the bend.

Abstract: A plasma coating system includes at least one coating station with a first side and a second side defining a pathway with at least one bend. The coating station also includes a first plasma arc that provides a plasma jet directed towards a substrate. The first plasma arc is positioned on either the first side or the second side of the bend.

Abstract: Described are processes for repairing plastic glazing and for the local application of a plasma coating using a plasma depositing device to an edge created by the removal of excess or unwanted plastic from plastic.

Abstract: A system to coat a substrate includes a deposition chamber maintained at sub-atmospheric pressure, one or more arrays containing two or more expanding thermal plasma sources associated with the deposition chamber, and at least one injector containing orifices for each array. The substrate is positioned in the deposition chamber and each expanding thermal plasma source produces a plasma jet with a central axis, while the injector injects vaporized reagents into the plasma to form a coating that is deposited on the substrate. The injector orifices are located within a specified distance from the expanding thermal plasma source to obtain generally a coating with generally uniform coating properties.

Abstract: A system for coating a substrate includes a heater that heats the substrate. The heater includes a two-dimensional array of a plurality of heat sources which supply heat to the substrate when the substrate is in the presence of the array of heat sources. The heater further includes a controller that controls the operation of each heat source to heat a localized area of the surface of the substrate according to a predetermined temperature profile for the substrate.

Abstract: A multi-pass coating system and method for applying multiple coatings to substrates traversed through the system. The system includes at least one vacuum pump coupled to the system to establish a sub-atmospheric pressure within the system. The system also includes a least one coating zone where a coating layer is applied to the substrate and includes at least one transfer lock through which the substrates transition between atmospheric pressure outside the system and the sub-atmospheric pressure inside the system. To move the substrates through the system, the system includes a transport mechanism configured to move the substrates at least two times through the coating zone prior to the substrates being exited from the system.

Abstract: A system for coating a substrate includes a heater that heats the substrate. The heater includes a two-dimensional array of a plurality of heat sources which supply heat to the substrate when the substrate is in the presence of the array of heat sources. The heater further includes a controller that controls the operation of each heat source to heat a localized area of the surface of the substrate according to a predetermined temperature profile for the substrate.

Abstract: An apparatus and method for coating a substrate moved along a path of travel through the apparatus. A plasma source issues a plasma jet into which a first reagent is injected from a discharge orifice located upstream of the jet. A second reagent is injected into the jet from a discharge orifice located downstream of the jet. A controller is configured to regulate the flow of the first reagent according to a first set of parameters and regulate the flow of the second reagent according to a second set of parameters. As a result, the first and second reagents are applied to the substrate to form at least one layer of a coating on the substrate.

Abstract: An economical method of manufacturing a plastic glazing panel having an encapsulation for aesthetic purposes and to enhance the sealing of the glazing panel to the vehicle is presented. This economical method includes the steps of forming forming a plastic panel having an A-side and B-side; printing an opaque border from an ink with the border being in contact with the B-side of the panel and substantially encircling the perimeter of the panel; curing the ink of the opaque border; applying a weatherable layer on the printed border and the plastic panel; curing the weatherable layer; depositing an abrasion resistant layer on the weatherable layer; placing the plastic panel into a mold having a soft gasket; injecting an elastomeric material to form an encapsulation that substantially encircles the perimeter of the plastic panel and encompasses the A-side; B-side and edge of the plastic panel; and removing the plastic panel from the mold.

Abstract: This invention relates to plastic glazing assemblies for vehicle tops, windows, headlamps, and taillights, as well as residential and commercial glazing, aircraft glazing, and sunglasses. More specifically, a method of manufacturing a plastic glazing assembly exhibiting a high level of weatherability and abrasion resistance is disclosed which integrates the in-mold application of a coating and the subsequent deposition of an abrasion resistant layer to a molded plastic part.

Abstract: A plastic glazing system having weatherable coating for automotive windows is disclosed. The system comprises a transparent plastic substrate comprising an inner surface and an outer surface. The system further comprises a first weathering layer disposed on the outer surface of the substrate. The weathering layer comprises one of a polyurethane and a polyurethane-acrylate. The first weathering layer has a predetermined glass transition temperature. The system further comprises a first abrasion-resistant layer disposed on the first weathering layer. The first abrasion-resistant layer is compatible with the one of a polyurethane and a polyurethane-acrylate.

Abstract: A method and apparatus for stabilizing an incidental coating in a substrate coating apparatus is provided. The method includes defining interior surfaces of a coating zone in the substrate coating apparatus. The method may include preheating interior surfaces to a local preheat temperature that is approximately equal to a local coating temperature attained by the surfaces during coating of a substrate, at least partially defining the interior surfaces with a compliant fabric, or at least partially defining the interior surfaces with a compliant fabric and preheating the interior surfaces.

Abstract: A system for coating a side surface of a moving substrate. The system includes an array of plasma sources, a first plurality of orifices located upstream of the array and a second plurality of orifices located downstream of the array. A coating reagent is injected from each orifice into a plasma jet issuing from plasma source associated with that orifice. A controller modulates the flow of coating reagent and the flow flush gas to the orifices according to the contours of the substrate and to the position of the substrate relative to the array. An additional plasma array and set of orifices may be employed to coat the opposite side surface of the substrate.

Abstract: A window defroster assembly for use in a motor vehicle includes a transparent panel and a defroster grid integrally formed with the transparent panel by means of a robotic dispensing mechanism. The defroster includes conductive first and second busbars and a plurality of conductive grid lines extending between and connected to the first and second busbars.

Abstract: An automotive glazing panel is provided by a polycarbonate substrate having a coating system including an inner layer blocking IR and overlying coating material blocking UV radiation and providing a scratch resistant outer coating layer.

Abstract: An automotive glazing panel is provided by a polycarbonate substrate having a coating system including an inner layer blocking IR and overlying coating material blocking UV radiation and providing a scratch resistant outer coating layer.

Abstract: The invention is a method of depositing a rugate filter coating on a substrate, with the coating having an index of refraction that varies with the depth thereof.

Abstract: Capacitors with high dielectric strength and low dissipation factor over a wide range of frequencies comprise two or more conductive layers separated by at least one dielectric layer. The dielectric layer is of silicon-doped amorphous hydrogenated carbon, with suitable dopants including silane (which is preferred), tetraalkoxysilanes and polyorganosiloxanes.