Electrolysis: processes – compositions used therein – and methods – Electrolytic coating – Forming nonelectrolytic coating after depositing...
Reexamination Certificate
1999-03-08
2001-04-24
Wong, Edna (Department: 1741)
Electrolysis: processes, compositions used therein, and methods
Electrolytic coating
Forming nonelectrolytic coating after depositing...
C205S180000, C205S181000, C205S118000, C205S120000, C205S122000
Reexamination Certificate
active
06221231
ABSTRACT:
FIELD OF THE INVENTION
The present invention is directed to a method of applying protective and decorative coatings to articles.
BACKGROUND OF THE INVENTION
Providing an article such as, for example, a brass faucet or lock with a multilayered coating by depositing a first coating layer or series of coating layers by electroplating and then depositing a second coating layer or series of coating layers on the electroplated coating layer by physical vapor deposition is known in the art. Such a multilayered coating provides abrasion and corrosion protection to the article, is decorative, and levels off any imperfections such as nicks and scratches on the article. Thus, for example, a brass article having a duplex nickel layer comprised of bright nickel and semi-bright nickel electroplated thereon and a zirconium nitride layer deposited on the duplex nickel layer by physical vapor deposition is smooth, has improved abrasion and corrosion resistance, and has the color of polished brass.
It is generally the vapor deposited layer which provides the abrasion protection and decorative appearance. However, the vapor deposited coating layer is generally quite thin, typically in the range of from about one to 20 millionths of an inch. Due to the thinness of the vapor deposited coating any water spots or any other surface defects such as nickel or chrome stains from or caused by the electroplating process show through and indeed are accentuated by the thin vapor deposited coating. Even spots, stains or discolorations which are not visible to the naked eye on the electroplated article will become visible after the vapor deposited coating is applied.
It is thus currently necessary to thoroughly inspect, clean and dry each article as it comes out of the electroplating bath. One conventional way of cleaning the electroplated articles is to run the articles through a water based cleaning system and use nitrogen drying to dry the articles. This is quite expensive and not always successful. Another method involves hand drying and cleaning each individual article. This hand drying, while more effective than a nitrogen based drying system, is very labor intensive and, therefore, also quite expensive. Hand drying also involves handling the electroplated articles which may result in dropping or bumping the articles against other objects with consequent damage to the articles.
It would be very advantageous if an efficient and effective drying method for the electroplated articles were available which eliminated the problems associated with conventional, currently used cleaning and drying methods. It is an object of the instant invention to provide such a system.
SUMMARY OF THE INVENTION
The instant invention comprises a method of applying a multi layer protective and decorative coating to an article. The method involves first applying at least one coating layer by electroplating. The electroplated article is then removed from the electroplating bath and subjected to pulse blow drying for spot-free drying. Then at least one layer is vapor deposited on the electroplated article by chemical vapor deposition.
The electroplating comprises applying at least one layer selected from copper, nickel and chrome. The copper plating includes both alkaline copper plating and acid copper plating. The nickel plating includes the electroplating of bright nickel, semi-bright nickel, and a duplex nickel layer comprised of bright nickel and semi-bright nickel.
Before the electroplated article is subjected to a chemical vapor deposition process in order to apply at least one thin chemically vapor deposited coating layer onto the electroplated coating the article is pulse blow dried in order to remove any wet spots or nickel or chrome stains.
After pulse blow drying at least one coating layer is deposited by chemical vapor deposition onto the top electroplated layer. The vapor deposited layer or layers are selected from non-precious refractory metals, non-precious refractory metal alloys, non-precious refractory metal compounds, and non-precious refractory metal alloy compounds. The non-precious refractory metal compounds and non-precious refractory metal alloy compounds include the nitrides, oxides, carbides, carbonitrides, and reaction products of a refractory metal or refractory metal alloy, oxygen and nitrogen.
REFERENCES:
patent: 4938999 (1990-07-01), Jenkin
patent: 5879532 (1999-03-01), Foster et al.
Doigan Lloyd D.
Kapustij Myron B.
Masco Corporation of Indiana
Wong Edna
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