Dishwaser with electrocoated dish rack

Abstract

The invention relates to a dish rack with a protective coating comprising an electrocoated layer and a polymer layer. The coating also includes a base corrosion-resistant layer on the metallic dish rack and a primer layer adjacent to the electrocoated layer to improve adhesion of the polymer layer. The aesthetically appealing exterior coating protects the dish rack from corrosion and from corrosion propagation.

1 . A dish rack for an automated dishwasher, comprising: 
 a metal frame configured to support dishes, and    an exterior coating covering at least a portion of the metal frame and comprising: 
 an electrocoated layer on the metal frame, and  
 a polymer layer on the electrocoated layer;  
   whereby the exterior coating protects the metal frame from corrosion while providing an aesthetic appearance.    
   
   
       2 . The dish rack according to  claim 1  wherein the electrocoated layer is non-metallic.  
   
   
       3 . The dish rack according to  claim 1  wherein the electrocoated layer is a paint layer.  
   
   
       4 . The dish rack according to  claim 3  wherein the paint layer is non-metallic.  
   
   
       5 . The dish rack according to  claim 1  wherein the polymer layer is a thermoplastic.  
   
   
       6 . The dish rack according to  claim 5  wherein the thermoplastic is a non-hydrocarbon carbon-chain polymer.  
   
   
       7 . The dish rack according to  claim 6  wherein the non-hydrocarbon carbon chain polymer is a polyvinyl chloride.  
   
   
       8 . The dish rack according to  claim 5  wherein the thermoplastic is a polyvinyl chloride blend.  
   
   
       9 . The dish rack according to  claim 1  wherein the metal frame comprises a wire-form having multiple interconnected wires.  
   
   
       10 . The dish rack according to  claim 9  wherein the wire form defines a bottom wall and a peripheral wall extending upwardly from the bottom wall to form an open-top, dish-holding recess.  
   
   
       11 . The dish rack according to  claim 10  and the wire form further comprising at least one set of tines located within the dish-holding recess.  
   
   
       12 . The dish rack according to  claim 1  wherein the entire metal frame is covered by the exterior coating.  
   
   
       13 . The dish rack according to  claim 1  wherein the exterior coating further comprises a primer layer between the electrocoated layer and the polymer layer.  
   
   
       14 . The dish rack according to  claim 13  wherein the primer layer comprises a water-based primer.  
   
   
       15 . The dish rack according to  claim 13  wherein the primer layer comprises a non-water-based primer.  
   
   
       16 . The dish rack according to  claim 15  wherein the primer layer comprises an acetone-based primer.  
   
   
       17 . The dish rack according to  claim 15  wherein the primer layer comprises a methyl ethyl ketone-based primer.  
   
   
       18 . The dish rack according to  claim 13  wherein the electrocoated layer is non-metallic.  
   
   
       19 . The dish rack according to  claim 13  wherein the electrocoated layer is a paint layer.  
   
   
       20 . The dish rack according to  claim 19  wherein the paint layer is non-metallic.  
   
   
       21 . The dish rack according to  claim 19  wherein the polymer layer is a thermoplastic.  
   
   
       22 . The dish rack according to  claim 21  wherein the thermoplastic is a non-hydrocarbon carbon-chain polymer.  
   
   
       23 . The dish rack according to  claim 22  wherein the non-hydrocarbon carbon chain polymer is a polyvinyl chloride.  
   
   
       24 . The dish rack according to  claim 21  wherein the thermoplastic is a polyvinyl chloride blend.  
   
   
       25 . The dish rack according to  claim 21  and further comprising a corrosion-resistant layer between the electrocoated layer and the metal frame.  
   
   
       26 . The dish rack according to  claim 25  wherein the corrosion-resistant layer comprises an iron phosphate layer.  
   
   
       27 . The dish rack according to  claim 25  wherein the corrosion-resistant layer comprises a zinc phosphate layer.  
   
   
       28 . The dish rack according to  claim 25  wherein the corrosion-resistant layer comprises a tri-chrome sealer layer.  
   
   
       29 . An automated dishwasher, comprising: 
 a wash tub having top, bottom, side, and rear walls, which collectively form an open-faced wash chamber;    a door hingedly mounted relative to the wash tub for movement between an open and closed conditions to selectively close the open-faced wash chamber;    a dish rack located within the open-faced wash chamber and comprising a metal frame configured to support dishes; and    an exterior coating covering at least a portion of the metal frame and comprising: 
 an electrocoated layer on the metal frame, and  
 a polymer layer on the electrocoated layer;  
   whereby the exterior coating protects the metal frame from corrosion while providing an aesthetic appearance.    
   
   
       30 . The automated dishwasher according to  claim 29  wherein the exterior coating further comprises a primer layer between the electrocoated layer and the polymer layer.  
   
   
       31 . The automated dishwasher according to  claim 30  wherein the primer layer comprises a water-based primer.  
   
   
       32 . The automated dishwasher according to  claim 30  wherein the primer layer comprises a non-water-based primer.  
   
   
       33 . The automated dishwasher according to  claim 32  wherein the primer layer comprises an acetone-based primer.  
   
   
       34 . The automated dishwasher according to  claim 32  wherein the primer layer comprises a methyl ethyl ketone-based primer.  
   
   
       35 . The automated dishwasher according to  claim 30  wherein the electrocoated layer is non-metallic.  
   
   
       36 . The automated dishwasher according to  claim 30  wherein the electrocoated layer is a paint layer.  
   
   
       37 . The automated dishwasher according to  claim 36  wherein the paint layer is non-metallic.  
   
   
       38 . The automated dishwasher according to  claim 30  wherein the polymer layer is a thermoplastic.  
   
   
       39 . The automated dishwasher according to  claim 38  wherein the thermoplastic is a non-hydrocarbon carbon-chain polymer.  
   
   
       40 . The automated dishwasher according to  claim 39  wherein the non-hydrocarbon carbon chain polymer is a polyvinyl chloride.  
   
   
       41 . The automated dishwasher according to  claim 38  wherein the thermoplastic is a polyvinyl chloride blend.  
   
   
       42 . The automated dishwasher according to  claim 38  and further comprising a corrosion-resistant layer between the electrocoated layer and the metal frame.  
   
   
       43 . The automated dishwasher according to  claim 42  wherein the corrosion-resistant layer comprises an iron phosphate layer.  
   
   
       44 . The automated dishwasher according to  claim 42  wherein the corrosion-resistant layer comprises a zinc phosphate layer.  
   
   
       45 . The automated dishwasher according to  claim 42  wherein the corrosion-resistant layer comprises a tri-chrome sealer layer.