METHOD OF COATING A CAST ALLOY WHEEL PROVIDING A TWO-TONE APPEARANCE
A cast wheel having an alloy substrate includes a primary surface and a secondary surface. A first polymeric coating is applied to the primary surface and to the secondary surface sealing the cast alloy wheel within the first polymeric coating. An intermediate polymeric coating is applied over the first polymeric coating. The intermediate polymeric coating is coated with metal using physical vapor deposition with the metal being aesthetically distinguishable from the first polymeric coating. A third polymeric coating is applied over the metal. The third polymeric coating, the intermediate coating and the metal from the primary surface of the cast alloy wheel are removed aesthetically distinguishing the primary surface from the secondary surface. A fourth polymeric coating is applied over the primary surface and the secondary surface.
The present application is a Divisional Patent Application claiming priority to U.S. patent application Ser. No. 15/349,761 filed Nov. 11, 2016, which claims priority to U.S. Provisional Patent Application No. 62/253,923 filed Nov. 11, 2015, the contents of which are incorporated herein by reference.
TECHNICAL FIELDThe present application relates generally toward a process for coating cast alloy wheels. More specifically, the present application relates toward a method of coating a cast alloy wheel to achieve a unique metallic, two-tone color appearance.
BACKGROUNDCast alloy wheels have been increasing in market share for many years. Cast alloys provide both weight reduction and unique appearance not available to old style steel. Wheels decorated with hubcaps. Various methods for providing a durable and aesthetically pleasing coating to cast alloy wheels have varied widely. Early versions of cast alloy wheels were coated with lacquer paint, which provided aesthetically pleasing qualities, but did not provide necessary durability. Later generations of cast alloy wheels were coated with multi-layer paint systems that included primers, colorization or base coats, and a clear coat to provide a high level of gloss to the alloy wheel. In some instances, the paint coatings are removed so that the substrate of the cast alloy is exposed to achieve a unique, “bright metallic surface” over- which a clear coat is applied.
Later generations of cast alloy wheels have been provided with a metallic finish without requiring significant machining to provide a metallic aesthetic by exposing the cast alloy substrate. One such example is the use of physical vapor deposition (PVD) used to apply various alloys and metals such as, for example, aluminum, chromium, titanium, silver, nickel, and even gold over one or more layers of paint or primer that are applied to the substrate to provide a sufficiently smooth surface to receive the PVD metal coat. PVD processes have been used to coat wheels and are disclosed in U.S. Pat. No. 5,656,335, the contents of which are enclosed herein by reference.
However, consumers of vehicles having cast alloy wheels demand ever-improving and unique aesthetic qualities, such as, for example, two-tone or even multi-tone appearance providing various colors to the visible surface of the cast alloy wheel. Therefore, it would be desirable to provide a two-tone appearance to a cast alloy wheel while still making use of the desirable qualities provided by PVD coatings not presently available.
SUMMARYA cast alloy wheel includes a primary surface and a secondary surface. The first polymeric coating is applied to the primary surface and to the secondary surface to seal the cast alloy wheel. An intermediate polymeric coating is applied over the first polymeric coating. The intermediate polymeric coating is subsequently coated with a metal using a physical vapor deposition process where the metal is aesthetically distinguishable from the first polymeric coating. A third polymeric coating is applied over the metal. The third polymeric coating, the intermediate polymeric coating, and the metal are removed from the primary cast alloy wheel exposing the first polymeric coating to aesthetically distinguish the primary surface from the secondary surface. A fourth polymeric coating is applied over the primary surface and the secondary surface.
Inventive coating method of the present application provides a smooth metallic appearance along with a two-tone quality without having to expose the metallic alloy substrate of a wheel. The metallic alloy provides an appreciable metallic appearance to the wheel with a two-tone quality after removal of a portion of the metallic coating from the primary surface of the wheel. Therefore, enhanced aesthetic qualities not previously available on cast alloy wheels are now achievable providing that unique two-tone appearance taking advantage of the best features of the PVD applied metal and a polymeric coating.
Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description, when considered in connection with the accompanying drawings, wherein:
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An intermediate polymeric coating 36 is applied over the first polymeric coating 34. The intermediate polymeric coating 36 is contemplated to be applied by way of a spray system, being either powder or liquid. The intermediate polymeric coating 36 is smoother than the first polymeric coating 34 and provides a high gloss appearance. In addition, the intermediate polymeric coating 36 includes a film thickness between about 100 microns and 150 microns. In one embodiment, the intermediate polymeric coating 36 is not pigmented to provide any visible coloration, but is clear or substantially transparent. In an alternative embodiment, the intermediate polymeric coating 36 is pigmented to achieve an identical or similar color as the first polymeric coating 34, or, in the alternative, a distinguishing color from the first polymeric coating 34, the purpose of which will become more evident herein below.
A metallic layer 38 is applied over the intermediate polymeric coating 36 using a PVD process to achieve a reflective or mirrored metallic appearance or finish. As such, various metals including, but not limited to, chromium, nickel, aluminum, silver, gold and even alloys are applied by the PVD process set forth in U.S. Pat. No. 5,656,335, or an equivalent process, the contents of which are included herein by reference, and will not be further discussed. The high gloss intermediate polymeric coating 36 enhances the mirrored appearance of the metallic layer 38. The PVD process encapsulates the wheel 10, and the first polymeric coating with the metal. As used herein, encapsulates and encapsulating includes substantial encapsulation where some gaps may exists as part of process variability and further includes encapsulating primary and secondary surfaces 24, 26 of the vehicle wheel 10. Having achieved a desirable roughness value of the intermediate polymeric coating 36, the metallic layer 38 can provide a bright, shiny finish achieving a desirable and aesthetically pleasing gloss representative of a machined or polished substrate. In one embodiment, the metallic layer 38 includes a film thickness of between 0.1 microns and 0.3 microns. The metal forming the metallic layer 38 forms a physical and molecular bond to the intermediate polymer coating 36 providing desirable adhesion desirable for further processing.
A third polymeric coating 40 is applied over the metallic layer 38. In one embodiment, the third polymeric coating 40 is a clear coating providing no pigmentation. The coating is contemplated to be a urethane, acrylic, polyester, or any other polymer coating capable of achieving desired performance characteristics. When not pigmented, the third polymeric coating 40 provides additional gloss to the metallic layer 38. In an alternative embodiment, the third polymeric coating 40 is lightly pigmented to provide alternate color appearance to the metallic layer 38, which is contemplated to include opalescent pigments and other light reflective properties.
After the third polymeric coating has been applied, the wheel 10 is placed in a precision lathe, or equivalent machine and at the primary surface 24 a predetermined portion of the intermediate polymeric coating 36, the metallic layer 38, and the third polymeric coating 40 is removed exposing the first polymeric coating 34. It is contemplated that the same lathe may be used to remove the various layers 36, 38, and 40 from the primary surface as performs the pre-machining. In one embodiment, between about 125 microns and 180 microns of the first polymeric coating 34 are removed. Therefore, a two-tone appearance is achieved when the first polymeric coating 34 is pigmented in a manner to distinguish the first polymeric coating 34 from the metallic layer 34. Pre-machining the primary surface 24 is believed to reduce fallout where the wheel substrate 32 might be exposed due to undesirable surface roughness when removing 125 microns to 180 microns of the first polymeric coating 34.
In another embodiment, the intermediate polymeric coating 36 is not visible either by a contour machined at the primary surface 24, or because the pigmentation, or lack of pigmentation makes the intermediate polymeric coating 36 indistinguishable from the first polymeric coating 34. Alternatively, the intermediate polymeric coating 36 is distinguishable from the first polymeric coating 34 providing a bead 37 or appearance of a pin stripe circumscribing the predetermined portion of the primary surface 24.
Once the desirable two-tome effect has been achieved, a final clear polymeric coating 42 is applied over, at least the primary surface 24 of the Wheel 10. Alternatively, the primary surface 42 and the secondary surface 26 of the wheel 10 are coated with the clear polymeric coating 42 to achieve a consistent gloss level throughout the visible spectrum of the wheel 10. However, prior to applying the final clear polymeric coating 42, the wheel is subjected to cleaning and further pretreatment to prevent dirt and contamination from being entrapped in the final clear polymeric coating 42. It should be understood by those of ordinary skill in the art that the combination of paint and metallic layers, after the application of the clear polymeric coating 42 includes a substantially common film thickness at the primary surface 24 of the wheel 10. However, it is further contemplated that the combined film thickness at the secondary surface 26 of the wheel 10 is somewhat less than that of the primary surface 24 of the wheel 10. It should be further understood that the intermediate polymeric coating 36 is optional and may not be applied. In this embodiment, the first polymeric coating 34 may include an additional thickness to achieve the desired combined film thickness.
An alternative embodiment is shown in
A further embodiment is shown in
Ultraviolet absorbers may also be included in any of the paint layers to prevent degradation of the paint, and even discoloration of the metallic layer 38. As set forth above, different pigmentation may also be included in either one of or both the third polymeric coating. 40 or the fourth polymeric coating 42. In addition, multiple metallic affects may be achieved by exposing the cast alloy substrate of the primary surface 24 to be contrasted by a complimentary or distinguishable metal 38 applied by PVD process.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. The foregoing invention has been described in accordance with relevant legal standards; thus, the description is merely exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment have become apparent to those skilled in the art and do come within the scope of this invention. Accordingly, the scope of the legal protection afforded this invention can only be determined by studying the following claims.
Claims
1. A method of coating a cast alloy wheel, comprising the steps of:
- providing a cast wheel having an alloy substrate including a primary surface and a secondary surface;
- applying a first polymeric coating being pigmented to said primary surface and to said secondary surface thereby sealing said cast alloy wheel within said first polymeric coating;
- coating the first polymeric coating with metal using vapor deposition with said metal being aesthetically distinguishable from said first polymeric coating;
- applying a second polymeric coating over said metal;
- removing said second polymeric coating and said metal from said primary surface of said cast alloy thereby exposing at least a portion of the first polymeric coating providing aesthetically distinguishing appearance of said first polymeric coating disposed upon said primary surface from said metal disposed upon said secondary surface; and
- applying a third polymeric coating over said primary surface and said secondary surface.
2. The method set forth in claim 1, further including a step of applying an intermediate polymer coating over said first polymer coating that is pigmented for being aesthetically distinguishable from said metal and from said first polymer coating and removing a portion of said intermediate coating at said primary surface thereby leaving a visible bead of said intermediate coating adjacent an edge of said metal.
3. The method set forth in claim 1, wherein said step of applying a third polymeric coating over said primary surface and said secondary surface is further defined by applying a clear third polymeric coating.
4. The method set forth in claim 1, wherein said step of applying a third polymeric coating over said primary surface and said secondary surface is further defined by applying a pigmented third polymeric coating and defining a visible bead of said first polymeric coating between said alloy substrate and said metal.
5. The method set forth in claim 1, further including a step of removing a portion said second polymeric coating at said primary surface thereby exposing said first polymeric coating while leaving a visible bead of said second polymeric coating between said first polymeric coating and an edge of said metal.
6. The method set forth in claim I, wherein said step of removing said second polymeric: coating and said metal at said primary surface is further defined by removing a portion of said first polymeric coating thereby creating an aesthetic contrast between said metal and said first polymeric coating.
7. The method set forth in claim 1, further including the step of removing said first polymeric coating thereby exposing said alloy substrate for creating an aesthetic contrast between said metal and said alloy substrate.
8. The method set forth in claim 7, further including a step of applying a clear polymeric coating over said substrate and said second polymeric coating.
9. The method set forth in claim 1, further including a step of applying an intermediate polymeric coating between said metal and said second polymeric coating, wherein said intermediate polymeric coating includes a higher gloss level than does the first polymeric coating and removing said metal and a portion of said intermediate coating thereby leaving a bead of said intermediate polymeric coating visible between said metal and said second polymeric coating.
10. The method set forth in claim 9, wherein said step of applying a said intermediate polymeric coating is further defined by said intermediate polymeric coating being one of a clear polymeric coating, a pigmented polymeric coating distinguishable from said first polymeric coating, or a pigmented polymeric coating being indistinguishable from said first polymeric coating.
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Type: Application
Filed: Jun 21, 2019
Publication Date: Oct 10, 2019
Inventors: Don Stebbins (Bloomfield Hills, MI), Thomas Schwing (Southfield, MI)
Application Number: 16/448,848