Decorative corrosion and abrasion resistant coating

Details Decorative corrosion and abrasion resistant coating Decorative corrosion and abrasion resistant coating

1999-03-01

2001-06-12

Turner, Archene (Department: 1775)

Stock material or miscellaneous articles

Composite

Of metal

C428S469000, C428S697000, C428S698000, C428S701000, C428S702000, C428S627000

Reexamination Certificate

active

06245435

ABSTRACT:

THE FIELD OF THE INVENTION
The present invention relates to decorative coatings for articles of manufacture such as faucets and related plumbing products including shower heads, escutcheons, tub spouts and the like. More specifically, the invention concerns a decorative coating for such a product, which is resistant to corrosion, abrasion and attack by chemicals, and has a specified decorative color other than brass. The invention is particularly concerned with such a decorative coating which resists corrosion, a common problem in many present-day decorative coatings, and uses only zirconium or hafnium as the principal component of the outer decorative layer. There are numerous prior art patents which disclose the use of zirconium to provide a corrosion resistant brass appearing decorative outer coating. However, attempts to apply the principles of such prior art disclosures to provide colors other than brass, through use of principal components for the outer coating other than zirconium or hafnium, have all resulted in failure. The present invention provides such a coating in which the color is other than brass, for example gray, gold or black, but uses zirconium or hafnium as the principal component of the outer layer, with the parameters of the physical vapor deposition process (PVD) being manipulated to provide an outer layer which has the desired resistance to corrosion, abrasion and attack from chemicals.
SUMMARY OF THE INVENTION
The present invention relates to articles of manufacture with a decorative coating other than brass and more specifically to such a coating which is resistant to corrosion, abrasion and attack by chemicals.
A primary purpose of the invention is to provide a new article of manufacture which has a specified decorative color, for example gray, gold or black, and includes an outer layer which has as a principal component only zirconium or hafnium.
Another purpose is an article of manufacture of the type described in which the outer layer applied by physical vapor deposition can provide different colors, depending upon the specific parameters of the deposition process, through the use of only zirconium or hafnium as the principal component of the outer layer.
Another purpose is an article of manufacture of the type described in which the substrate is essentially free of surface flaws and porosity and is chosen from the group comprising brass, a metal glass and zinc castings produced by a semi-solid or slush casting process.
Another purpose is a corrosion resistant article of manufacture of the type described, for example door hardware, or a faucet or related plumbing component, having enhanced corrosion resistance by the maintenance of a passivating layer on the exterior thereof.
Other purposes will appear in the ensuing specification, drawing and claims.


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