# US 2013/0280435 A1 · Plasma Coatings and Method of Making The Same

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- Number: US 2013/0280435 A1
- Document ID: US20130280435A1
- Status: Published application
- Kind: A1
- Application number: 13/917,064
- Filed: 2013-06-13
- Published: 2013-10-24
- Earliest claimed: 2008-08-26
- Assignees: Ford Global Technologies, LLC
- Applicants: Ford Global Technologies, LLC
- Inventors: Larry P. Haack; Ann Marie Straccia
- Web page: https://patentgrep.com/patent/US20130280435A1

## CPC

- C23C 4/134: Plasma spraying
- B05D 1/62: {Plasma-deposition of organic layers (plasma deposition in general C23C14/00, C23C16/00)}
- B05D 1/02: performed by spraying
- Y10T 428/24802: Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T 428/31504: Composite [nonstructural laminate]
- Y10T 428/31663: As siloxane, silicone or silane
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method of coating a substrate surface. The method includes plasma spraying a direct-spray component onto a substrate surface, and plasma spraying an over-spray component onto the substrate surface. The direct-spray and over-spray components form a plasma coating surface contacting at least a portion of the substrate surface.

## Claims

### Claim 1

(canceled)

### Claim 2

A method of coating a substrate surface comprising:
plasma spraying a direct-spray component onto a substrate surface; and
plasma spraying an over-spray component onto the substrate surface, the direct-spray and over-spray components forming a plasma coating surface contacting at least a portion of the substrate surface.

### Claim 3 (depends on 2)

The method of claim 2, wherein the first and second plasma spraying steps are performed simultaneously to form the plasma coating surface.

### Claim 4 (depends on 2)

The method of claim 2, wherein the direct-spray component includes a single bounded direct-spray region, and the over-spray component includes a single bounded over-spray region adjacent to the single bounded direct-spray region.

### Claim 5 (depends on 2)

The method of claim 2, wherein the direct-spray component includes a single bounded direct-spray region, and the over-spray component includes first and second discrete over-spray subcomponents including first and second bounded over-spray regions adjacent to the single bounded direct-spray region.

### Claim 6 (depends on 5)

The method of claim 5, wherein the first and second bounded over-spray regions are not adjacent to each other.

### Claim 7 (depends on 2)

The method of claim 2, wherein the direct-spray and over-spray components each have a different cross-linked polymer chemistry.

### Claim 8 (depends on 2)

The method of claim 2, wherein the first and second plasma spraying steps are performed in a single pass to form the plasma coating surface.

### Claim 9

A method of coating a substrate surface comprising:
plasma spraying a direct-spray component onto a substrate surface; and
plasma spraying an over-spray component onto the substrate surface, the direct-spray and over-spray components forming a plasma coating surface contacting less than the entire substrate surface.

### Claim 10 (depends on 9)

The method of claim 9, wherein the first and second plasma spraying steps are performed simultaneously to form the plasma coating surface.

### Claim 11 (depends on 9)

The method of claim 9, wherein the direct-spray component includes a single bounded direct-spray region, and the over-spray component includes a single bounded over-spray region adjacent to the single bounded direct-spray region.

### Claim 12 (depends on 9)

The method of claim 9, wherein the direct-spray component included a single bounded direct-spray region, and the over-spray component includes first and second discrete over-spray subcomponents including first and second bounded over-spray regions adjacent to the single bounded direct-spray region.

### Claim 13 (depends on 12)

The method of claim 12, wherein the first and second bounded over-spray regions are not adjacent to each other.

### Claim 14 (depends on 9)

The method of claim 9, wherein the direct-spray and over-spray components each have a different cross-linked polymer chemistry.

### Claim 15 (depends on 9)

The method of claim 9, wherein the first and second plasma spraying steps are performed in a single pass to form the plasma coating surface.

### Claim 16

A method of coating a substrate surface comprising:
plasma spraying a direct-spray component onto a substrate surface; and
plasma spraying an over-spray component onto the substrate surface, the direct-spray component and the over-spray component each having a different cross-linked polymer chemistry.

### Claim 17 (depends on 16)

The method of claim 16, wherein the first and second plasma spraying steps are performed in a single pass to form the plasma coating surface.

### Claim 18 (depends on 16)

The method of claim 16, the first and second plasma spraying steps are performed simultaneously to form the plasma coating surface.

### Claim 19 (depends on 16)

The method of claim 16, wherein the direct-spray component includes a single bounded direct-spray region, and the over-spray component includes a single bounded over-spray region adjacent to the single bounded direct-spray region.

### Claim 20 (depends on 16)

The method of claim 16, wherein the direct-spray component included a single bounded direct-spray region, and the over-spray component includes first and second discrete over-spray subcomponents including first and second bounded over-spray regions adjacent to the single bounded direct-spray region.

### Claim 21 (depends on 20)

The method of claim 20, wherein the first and second bounded over-spray regions are not adjacent to each other.