Method for providing a dual-layer coating on an automotive suspension product

A method for applying a protective coating to a metallic component of a vehicle comprising the steps of:

• applying a coat of epoxy-based, protective powder to the component;
• partially curing the coat of epoxy-based, protective powder, wherein the partially curing step includes the step of heating the component with the coat of epoxy-based, protective powder applied thereto in an oven at a predetermined temperature for a predetermined period of time;
• heating a fluidized bed of thermoplastic powder;
• immersing the component with the partially cured coat of epoxy-based, protective powder into the heated fluidized bed of thermoplastic powder so as to apply a coat of the thermoplastic powder over the coat of epoxy-based, protective powder;
• withdrawing the component from the fluidized bed;
• finally curing the coat of epoxy-based, protective powder and the coat of the thermoplastic powder;
• monitoring a sum of the oven temperature and the temperature of the fluidized bed of thermoplastic powder;
• and
• maintaining the sum of the oven temperature and the temperature of the fluidized bed of thermoplastic powder within a predetermined temperature range.

A method for applying a protective coating to a metallic component of a vehicle comprising the steps of:

• applying a coat of epoxy-based, protective powder to the component;
• partially curing the coat of epoxy-based, protective powder, wherein the partially curing step includes the step of heating the component with the coat of epoxy-based, protective powder applied thereto in an oven at a predetermined temperature for a predetermined period of time;
• heating a fluidized bed of thermoplastic powder;
• immersing the component with the partially cured coat of epoxy-based, protective powder into the heated fluidized bed of thermoplastic powder so as to apply a coat of the thermoplastic powder over the coat of epoxy-based, protective powder;
• withdrawing the component from the fluidized bed;
• finally curing the coat of epoxy-based, protective powder and the coat of the thermoplastic powder;
• monitoring a sum of the component temperature at the time just prior to the immersing step and the temperature of the fluidized bed of thermoplastic powder;
• and
• maintaining the sum of the component temperature at the time just prior to the immersing step and the temperature of the fluidized bed of thermoplastic powder within a predetermined temperature range.

A batch method for applying a protective coating to multiple groups of steel components for a vehicle comprising the steps of:

• applying a coat of epoxy-based, protective powder to a group of the components at a first coat station;
• partially curing the coat of epoxy-based, protective powder on the group of the components at a gelling station;
• pre-heating a fluidized bed of thermoplastic powder, wherein the fluidized bed of thermoplastic powder is pre-heated to bring the fluidized bed of thermoplastic powder within a predetermined temperature difference from the temperature of the group of components as detected between the gelling station and the second coat station;
• immersing the group of the components with the partially cured coat of epoxy-based, protective powder into the pre-heated fluidized bed of thermoplastic powder so as to apply a coat of the thermoplastic powder over the coat of epoxy-based, protective powder at a second coat station;
• finally curing the coat of epoxy-based, protective powder and the coat of the thermoplastic powder on the group of components, at least in part, at a curing station;
• monitoring the temperature difference between the fluidized bed of thermoplastic powder and the group of components as detected between the gelling station and the second coat station;
• and
• responsive to the monitoring step, adjusting at least one of the temperature of the fluidized bed of thermoplastic powder and the temperature of the group of components as detected between the gelling station and the second coat station.

A batch method for applying a protective coating to multiple groups of steel components for a vehicle comprising the steps of:

• applying a coat of epoxy-based, protective powder to a group of the components at a first coat station;
• partially curing the coat of epoxy-based, protective powder on the group of the components at a gelling station, wherein the gelling station utilizes a gelling oven at a predetermined temperature for a predetermined period of time;
• pre-heating a fluidized bed of thermoplastic powder;
• immersing the group of the components with the partially cured coat of epoxy-based, protective powder into the pre-heated fluidized bed of thermoplastic powder so as to apply a coat of the thermoplastic powder over the coat at a second coat station;
• finally curing, at least in part, the coat of epoxy-based, protective powder and the coat of the thermoplastic powder on the group of components at a curing station;
• monitoring a sum of the gelling oven temperature and the temperature of the fluidized bed of thermoplastic powder;
• and
• maintaining the sum of the gelling oven temperature and the temperature of the fluidized bed of thermoplastic powder within a predetermined temperature range.

A batch method for applying a protective coating to multiple groups of steel components for a vehicle comprising the steps of:

• applying a coat of epoxy-based, protective powder to a group of the components at a first coat station;
• partially curing the coat of epoxy-based, protective powder on the group of the components at a gelling station, wherein the gelling station utilizes a gelling oven at a predetermined temperature for a predetermined period of time;
• pre-heating a fluidized bed of thermoplastic powder;
• immersing the group of the components with the partially cured coat of epoxy-based, protective powder into the pre-heated fluidized bed of thermoplastic powder so as to apply a coat of the thermoplastic powder over the coat of epoxy-based, protective powder at a second coat station;
• finally curing the coat of epoxy-based, protective powder and the coat of the thermoplastic powder on the group of components, at least in part, at a curing station;
• monitoring a sum of the temperature of the group of components between the gelling station and the second coat station and the temperature of the fluidized bed of thermoplastic powder;
• and
• maintaining the temperature sum within a predetermined temperature range.

A method for applying a dual-layer protective coating to a steel component of a vehicle comprising the steps of:

• applying a first coat of epoxy-based, protective powder to the component;
• partially curing the first coat on the component in an oven at a first temperature;
• immersing the component with the partially cured first coat in a fluidized bed of thermoplastic powder heated at a second temperature to provide a second coat on the component;
• finally curing the first and second coats on the component;
• and
• repeating the applying, partially curing, immersing and finally curing steps for a plurality of the components while controlling the thickness of the second coat by maintaining a sum of the first and second temperatures within a predetermined temperature range.

A method for applying a protective, dual-layer coating to a component of a vehicle comprising the steps of:

• applying a coat of first-coat powder to the component;
• partially curing the coat of first-coat powder;
• heating a fluidized bed of second-coat powder, wherein the fluidized bed of second-coat powder is heated so as to bring the fluidized bed of thermoplastic powder within a predetermined temperature difference from the temperature of the component at a time just prior to the immersing step;
• immersing the component with the partially cured coat of first-coat powder into the heated fluidized bed of second-coat powder so as to apply a coat of the second-coat powder over the coat of first-coat powder;
• withdrawing the component from the fluidized bed;
• finally curing the coat of first-coat powder and the coat of the second-coat powder;
• monitoring the temperature difference between the fluidized bed of second-coat powder and the component at the time just prior to the immersing step;
• and
• responsive to the monitoring step, adjusting at least one of the temperature of the fluidized bed of second-coat powder and the temperature of the component at the time just prior to the immersing step.

A method for applying a protective, dual-layer coating to a component of a vehicle comprising the steps of:

• applying a coat of first-coat powder to the component;
• partially curing the coat of first-coat powder, wherein the partially curing step includes the step of heating the component with the coat of first-coat powder applied thereto in an oven at a predetermined temperature for a predetermined period of time;
• heating a fluidized bed of second-coat powder;
• immersing the component with the partially cured coat of first-coat powder into the heated fluidized bed of second-coat powder so as to apply a coat of the second-coat powder over the coat of first-coat powder;
• withdrawing the component from the fluidized bed;
• finally curing the coat of first-coat powder and the coat of the second-coat powder;
• monitoring a sum of the oven temperature and the temperature of the fluidized bed of second-coat powder;
• and
• maintaining the sum of the oven temperature and the temperature of the fluidized bed of second-coat powder within a predetermined temperature range.

A method for applying a protective, dual-layer coating to a component of a vehicle comprising the steps of:

• applying a coat of first-coat powder to the component;
• partially curing the coat of first-coat powder;
• heating a fluidized bed of second-coat powder;
• immersing the component with the partially cured coat of first-coat powder into the heated fluidized bed of second-coat powder so as to apply a coat of the second-coat powder over the coat of first-coat powder;
• withdrawing the component from the fluidized bed;
• finally curing the coat of first-coat powder and the coat of the second-coat powder;
• monitoring a sum of the component temperature at the time just prior to the immersing step and the temperature of the fluidized bed of second-coat powder;
• and
• maintaining the sum of the component temperature at the time just prior to the immersing step and the temperature of the fluidized bed of second-coat powder within a predetermined temperature range.