Method for simultaneously curing powder underlayer coating and PVD deposition of thin film layer

Abstract

In the generalized method of the present invention a heat curable coating is first applied to an article of manufacture. Thereafter, an outer coating is applied to the article in a physical vapor deposition process, and the heat from the PVD process cures the first layer while the PVD coating is being deposited upon the article. In the preferred embodiments, the heat curable coating is a powder coating and the cathodic arc of the PVD process provides the heat that cures the powder coating. An infrared heat source within the PVD chamber may be utilized to preheat the powder coating which is typically composed of an epoxy-polymer compound. Articles of manufacture having the coating of the present invention formed thereon are manufactured with less energy and labor costs.

What I claim is:  
     
         1 . A method for coating an article of manufacture comprising the steps of: 
 applying a first coating to an article of manufacture, said first coating having the property that it requires a curing step to complete it;    depositing a second coating upon said first coating utilizing a physical vapor deposition (PVD) process, wherein said first coating is cured in said PVD process.    
     
     
         2 . A method as described in    claim 1    wherein said first coating is a powder coating and wherein said step of applying said first coating includes the step of using an electrostatic powder spray process to apply said first coating.  
     
     
         3 . A method described in    claim 2    wherein said curing step utilizes heat or ultraviolet energy.  
     
     
         4 . A method as described in    claim 3    wherein said first powder coating is applied in a thickness from approximately 10 microns to approximately 5 mils.  
     
     
         5 . A method as described in    claim 4    wherein said first coating is composed of a polyester, acrylic, epoxy compound, or hybrid combination thereof.  
     
     
         6 . A method as described in    claim 5    wherein said second coating is composed of a metal.  
     
     
         7 . A method as described in    claim 5    wherein said second coating is comprised of a metal based compound.  
     
     
         8 . A method as described in    claim 1    wherein said PVD process includes the utilization of a cathodic arc to produce energy to cure said first coating.  
     
     
         9 . A method as described in    claim 8    wherein said PVD process includes the utilization of a heating device to pre-heat said first coating prior to said utilization of a cathodic arc.  
     
     
         10 . A method for coating an article of manufacture comprising the steps of: 
 applying a first coating to an article of manufacture, said first coating having the property that it requires a curing step to cure it;    mounting said article of manufacture in a physical vapor deposition chamber;    creating a vacuum atmosphere within said chamber;    curing said powder layer within said chamber;    depositing material upon said powder layer during said curing step;    cooling said articles within said chamber;    dismounting said articles from within said chamber.    
     
     
         11 . A method as described in    claim 10    wherein said steps of curing said powder layer and depositing material are accomplished simultaneously.  
     
     
         12 . A method as described in    claim 10    wherein said curing step utilizes heat or ultraviolet energy.  
     
     
         13 . A method as described in    claim 12    wherein said powder layer is pre-heated within said chamber prior to said step of depositing material upon said powder layer.  
     
     
         14 . A method as described in    claim 12    wherein said curing step is accomplished utilizing energy generated by a cathodic arc.  
     
     
         15 . A method as described in    claim 12    wherein said powder layer has a thickness of from approximately 10 microns to approximately 5 mils prior to said curing step.  
     
     
         16 . A method as described in    claim 15    wherein said powder layer is comprised of an epoxy, a polyester, acrylic compound, or a hybrid combination thereof.  
     
     
         17 . A method as described in    claim 16    wherein said material is comprised of a metal or a metal based compound.  
     
     
         18 . An article of manufacture comprising: 
 a base object having an outer surface thereof;    a coating being disposed upon said outer surface;    said coating being comprised of a cured powder portion and a physical vapor deposition (PVD) created portion, and wherein said two portions are intermixed to form a single layer.    
     
     
         19 . An article of manufacture as described in    claim 18    wherein said cured powder portion is comprised of a polyester, acrylic, epoxy compound or hybrid combination thereof.  
     
     
         20 . An article of manufacture as described in    claim 19    wherein said PVD created portion is comprised of a metal or metal based compound.