Multi-layer anti-corrosive coating

Abstract

Method of providing a multilayer coating. The method includes applying a first coating layer, which is substantially a metal, having a thickness of approximately 25 microns to approximately 200 microns directly on and in contact with a substrate; applying a second coating layer, which is a mixture of the metal and a polymeric material, having a thickness of approximately 5 microns to approximately 200 microns directly on and in contact with the first coating layer; applying a third coating layer, which is substantially the polymeric material, having a thickness of approximately 5 microns to approximately 200 microns directly on and in contact with the second coating layer; and at least one of: heating the substrate to approximately the fusing temperature of the metal when applying the first coating layer; and heating the substrate to approximately the fusing temperature of the polymeric material when applying the third coating layer.

What is claimed as new and desired to be protected by Letters Patent of the United States is: 
     
         1 . A method of providing a multilayer coating comprising:
 applying a first coating layer, which is substantially a metal, having a thickness of approximately 25 microns to approximately 200 microns directly on and in contact with a substrate;   applying a second coating layer, which is a mixture of the metal and a polymeric material, having a thickness of approximately 5 microns to approximately 200 microns directly on and in contact with the first coating layer;   applying a third coating layer, which is substantially the polymeric material, having a thickness of approximately 5 microns to approximately 200 microns directly on and in contact with the second coating layer; and   at least one of:   heating the substrate to approximately the fusing temperature of the metal when applying the first coating layer; and   heating the substrate to approximately the fusing temperature of the polymeric material when applying the third coating layer.   
     
     
         2 . A method of providing a multilayer coating according to  claim 1 , wherein the substrate comprises at least one of iron, iron alloy, steel, copper, alloys of copper, nickel, alloys of nickel, concrete, wood, wood products, fiberglass, ceramic and plastic. 
     
     
         3 . A method of providing a multilayer coating according to  claim 1 , wherein the metal comprises at least one of zinc, aluminum, alloy of zinc-aluminum, magnesium, alloy of zinc-magnesium, alloy of aluminum-magnesium, indium, alloy of zinc-indium, alloy of aluminum-indium, alloy of magnesium-indium, gallium, alloy of zinc-gallium, alloy of aluminum-gallium, alloy of magnesium-gallium, alloy of indium-gallium, tellurium, alloy of zinc-tellurian, alloy of aluminum-tellurium, alloy of magnesium-tellurium, alloy of indium-tellurium, and alloy of gallium-tellurium. 
     
     
         4 . A method of providing a multilayer coating according to  claim 1 , wherein the polymeric material comprises at least one of polyethylene, polypropylene, nylon, polytetrafluorethylene (PTFE), ethylene methacrylate acid copolymer (EMAA), a thermoplastic material and a thermoset material; 
     
     
         5 . A multilayer corrosion resistant coating comprising:
 a first coating layer, which is substantially a metal, deposited directly on and in contact with a substrate;   a second coating layer, which is a mixture of the metal and a polymeric material, deposited directly on and in contact with the first coating layer; and   a third coating layer, which is substantially the polymeric material, deposited directly on and in contact with the second coating layer;   wherein the substrate comprises at least one of steel, copper, alloys of copper, nickel, alloys of nickel, concrete, wood, wood products, fiberglass, ceramic and plastic;   wherein the metal comprises at least one of zinc, aluminum, alloy of zinc-aluminum, magnesium, alloy of zinc-magnesium, alloy of aluminum-magnesium, indium, alloy of zinc-indium, alloy of aluminum-indium, alloy of magnesium-indium, gallium, alloy of zinc-gallium, alloy of aluminum-gallium, alloy of magnesium-gallium, alloy of indium-gallium, tellurium, alloy of zinc-tellurian, alloy of aluminum-tellurium, alloy of magnesium-tellurium, alloy of indium-tellurium, and alloy of gallium-tellurium;   wherein the polymeric material comprises at least one of polyethylene, polypropylene, nylon, polytetrafluorethylene (PTFE), ethylene methacrylate acid copolymer (EMAA), a thermoplastic material and a thermoset material;   wherein a thickness of the first coating layer is approximately 25 microns to approximately 200 microns;   wherein a thickness of the second coating layer is approximately 5 microns to approximately 200 microns; and   wherein a thickness of the third coating layer is approximately 5 microns to approximately 200 microns.   
     
     
         6 . The multilayer corrosion resistant coating of  claim 5 , wherein the metal comprises at least 99% zinc. 
     
     
         7 . The multilayer corrosion resistant coating of  claim 5 , wherein the metal comprises aluminum and zinc having an aluminum-zinc ratio of about 85% aluminum to about 15% zinc. 
     
     
         8 . The multilayer corrosion resistant coating of  claim 5 , wherein the substrate is a metallic material, and wherein the metal is anodic to the substrate. 
     
     
         9 . The multilayer corrosion resistant coating of  claim 5 , wherein, when the polymeric material comprises thermoset material, the thermoset material is a fusion bonded epoxy. 
     
     
         10 . The multilayer corrosion resistant coating of  claim 5 , wherein the first coating layer is approximately 50-100 microns, the second coating layer is approximately 5-100 microns, and the third coating layer is approximately 50-150 microns. 
     
     
         11 . The multilayer corrosion resistant coating of  claim 5 , wherein the first coating layer is approximately 70-80 microns, the second coating layer is approximately 20-30 microns, and the third coating layer is approximately 95-105 microns. 
     
     
         12 . A method of providing a multilayer coating comprising:
 applying a first coating layer, which is substantially a metal, having a thickness of approximately 25 microns to approximately 200 microns directly on and in contact with a substrate, wherein the first coating layer is applied at a fusing temperature of the metal;   applying a second coating layer, which is a mixture of the metal and a polymeric material, having a thickness of approximately 5 microns to approximately 200 microns directly on and in contact with the first coating layer, wherein the second coating layer is applied at a fusing temperature of the polymeric material; and   applying a third coating layer, which is substantially the polymeric material, having a thickness of approximately 5 microns to approximately 200 microns directly on and in contact with the second coating layer, wherein the third coating layer is applied at the fusing temperature of the polymeric material.   
     
     
         13 . The method of providing the multilayer coating of  claim 12 , wherein the first coating layer, the second coating layer and the third coating layer are applied sequentially using at least one of cold spray, thermal spray and plasma spray. 
     
     
         14 . The method of providing the multilayer coating of  claim 12 , further comprising at least one of:
 heating the substrate to approximately a fusing temperature of the metal when applying the first coating layer; and   heating the substrate to approximately a fusing temperature of the polymeric material when applying the third coating layer.   
     
     
         15 . The method of providing the multilayer coating of  claim 12 , wherein the applying of the second coating layer comprises:
 applying the polymeric material onto an outer surface of the first coating layer; and   embedding the metal into the polymeric material on the outer surface of the first coating layer.   
     
     
         16 . The method of providing the multilayer coating of  claim 12 , wherein the applying of the second coating layer comprises at least one of:
 mixing the polymeric material and the metal together prior to being applied as the second coating layer; and   mixing the polymeric material and metal together upon impact at an outer surface on which the second coating layer is applied.   
     
     
         17 . The method of providing a multilayer coating according to  claim 12 , wherein the substrate comprises at least one of iron, iron alloy, steel, copper, alloys of copper, nickel, alloys of nickel, concrete, wood, wood products, fiberglass, ceramic and plastic. 
     
     
         18 . The method of providing a multilayer coating according to  claim 12 , wherein the metal comprises at least one of zinc, aluminum, alloy of zinc-aluminum, magnesium, alloy of zinc-magnesium, alloy of aluminum-magnesium, indium, alloy of zinc-indium, alloy of aluminum-indium, alloy of magnesium-indium, gallium, alloy of zinc-gallium, alloy of aluminum-gallium, alloy of magnesium-gallium, alloy of indium-gallium, tellurium, alloy of zinc-tellurian, alloy of aluminum-tellurium, alloy of magnesium-tellurium, alloy of indium-tellurium, and alloy of gallium-tellurium. 
     
     
         19 . The method of providing a multilayer coating according to  claim 12 , wherein the polymeric material comprises at least one of polyethylene, polypropylene, nylon, polytetrafluorethylene (PTFE), ethylene methacrylate acid copolymer (EMAA), a thermoplastic material and a thermoset material. 
     
     
         20 . The method of providing a multilayer coating according to  claim 12 , wherein the multilayer coating forms a corrosion resistant coating for the substrate.