METHOD FOR PRODUCING COATED SUBSTRATES, COATED SUBSTRATES AND USE THEREOF

Abstract

The present disclosure relates to coated non-metallic substrates and coated metallic substrates and methods for producing such coated substrates. A variant of the method is characterized in that a mat or glossy coating is underneath a metallic layer obtained in some eases by way of vapor deposition and/or sputtering. In another variant, the metallic layer is sufficiently thin so that it remains transparent or translucent to visible light. The coated substrates may include multiple layers such as metallic layers, polysiloxane layers, a color layer, a conversion layer, a primer layer, and/or a transparent or colored layer. An application system for applying a metallic layer to at least one surface of a substrate may include a plasma generator and/or a corona system for treating one or more layers by plasma treatment and/or corona treatment.

Claims

1-25. (canceled)

26. A method for manufacturing a coated metallic substrate, comprising: A) providing a metallic substrate with at least one surface that is capable of being coated at least in part areas; B) providing an application system for applying a metallic layer to the at least one surface of the metallic substrate; C) providing at least one plasma generator and/or at least one corona system within the application system; D) cleaning the coatable surface of the metallic substrate; E) applying, with the application system, at least one metallic layer containing a second metal selected from the group consisting of titanium, hafnium and zirconium, or a second metal alloy selected from the group consisting of alloys of titanium, hafnium and zirconium, onto the coatable surface of the metallic substrate; F) treating, by plasma treatment and/or corona treatment, the coatable surface of the metallic substrate or the metallic layer applied to the coatable surface of the metallic substrate according to step E); G) treating the coatable surface of the metallic substrate or the metallic layer applied to the coatable surface of the metallic substrate with at least one organosilicon compound by way of plasma polymerization to form a polysiloxane layer; H) treating, by plasma treatment and/or corona treatment, the polysiloxane layer formed according to step G); I) applying a conversion layer onto at least one of the coatable surface of the metallic substrate, the metallic layer applied according to step E), or the polysiloxane layer formed according to step G); J) treating, by plasma treatment and/or corona treatment, the conversion layer; K) treating the conversion layer with at least one organosilicon compound by way of plasma polymerization to form a treated polysiloxane layer; L) treating, by plasma treatment and/or corona treatment, the treated polysiloxane layer formed according to step K); M) applying at least one primer layer onto at least one of the coatable surface of the metallic substrate, the metallic layer applied according to step E), the polysiloxane layer formed according to step G), the conversion layer, or the treated polysiloxane layer formed according to step K); N) treating, by plasma treatment and/or corona treatment, the primer layer; O) treating the primer layer with at least one organosilicon compound by way of plasma polymerization to form a polysiloxane layer; P) treating, by plasma treatment and/or corona treatment, the polysiloxane layer formed according to step 0); P-Q) applying at least one matt coating or applying at least one gloss coating; Q) applying, with the application system, at least one metallic layer containing a first metal selected from the group consisting of aluminum, silver, gold, lead, vanadium, manganese, magnesium, iron, cobalt, molybdenum, tungsten, nickel, copper, chromium, palladium, platinum, titanium, zirconium and zinc, or containing a first metal alloy selected from the group consisting of brass, bronze, steel, alloys of aluminum, magnesium and titanium, onto the primer layer; R) treating, by plasma treatment and/or corona treatment, the metallic layer applied according to step Q); S) treating the metallic layer applied according to step Q) with at least one organosilicon compound by way of plasma polymerization to form a polysiloxane layer; T) treating, by plasma treatment and/or corona treatment, the polysiloxane layer formed according to step S); and U) applying at least one transparent and/or colored overcoat onto the metallic layer applied according to step Q) or onto the polysiloxane layer treated according to step T).

27. The method according to claim 26, wherein in step Q) the metallic layer is applied with a thickness such that the metallic layer is not transparent and is not translucent for visible light.

28. The method according to claim 26, wherein steps S) and T) are conducted prior to step U).

29. A method for manufacturing a coated metallic substrate, comprising: A) providing a metallic substrate with at least one surface that is capable of being coated at least in part areas; B) providing an application system for applying a metallic layer to the at least one surface of the metallic substrate; C) providing at least one plasma generator and/or at least one corona system within the application system; D) cleaning the coatable surface of the metallic substrate; E) applying, with the application system, at least one metallic layer containing a second metal selected from the group consisting of titanium, hafnium and zirconium, or a second metal alloy selected from the group consisting of alloys of titanium, hafnium and zirconium, onto the coatable surface of the metallic substrate; F) treating, by plasma treatment or corona treatment, the coatable surface of the metallic substrate or the metallic layer applied to the coatable surface of the metallic substrate according to step E); G) treating the coatable surface of the metallic substrate or the metallic layer applied to the coatable surface of the metallic substrate with at least one organosilicon compound by way of plasma polymerization to form a polysiloxane layer; H) treating, by plasma treatment and/or corona treatment, the polysiloxane layer formed according to step G); I) applying a conversion layer onto at least one of the coatable surface of the metallic substrate, the metallic layer applied according to step E), or the polysiloxane layer formed according to step G); J) treating, by plasma treatment and/or corona treatment, the conversion layer; K) treating the conversion layer with at least one organosilicon compound, by way of plasma polymerization, to form a treated polysiloxane layer; L) treating, by plasma treatment and/or corona treatment, the treated polysiloxane layer formed according to step K); M) applying at least one primer layer onto at least one of the coatable surface of the metallic substrate, the metallic layer applied according to step E), the polysiloxane layer formed according to step G), the conversion layer, or the treated polysiloxane layer formed according to step K); N) treating, by plasma treatment and/or corona treatment, the primer layer; O) treating the primer layer with at least one organosilicon compound, by way of plasma polymerization, to form a polysiloxane layer; P) treating, by plasma treatment and/or corona treatment, the polysiloxane layer formed according to step 0); Q) applying, with the application system, at least one metallic layer containing a first metal selected from the group consisting of aluminum, silver, gold, lead, vanadium, manganese, magnesium, iron, cobalt, molybdenum, tungsten, nickel, copper, chromium, palladium, platinum, titanium, zirconium and zinc, or containing a first metal alloy selected from the group consisting of brass, bronze, steel, alloys of aluminum, magnesium and titanium, onto at least one of the coatable surface of the metallic substrate, the metallic layer applied according to step E), the polysiloxane layer formed according to step G), the conversion layer, the polysiloxane layer, the primer layer, or the treated polysiloxane layer formed according to step K), whereby the metallic layer is applied in a thickness such that the metallic layer is transparent or translucent for visible light; R) treating, by plasma treatment and/or corona treatment, the metallic layer applied according to step Q); S) treating the metallic layer obtained according to step Q) with at least one organosilicon compound by way of plasma polymerization to form a polysiloxane layer; T) treating, by plasma treatment and/or corona treatment, the polysiloxane layer formed according to step S); and U) applying at least one transparent and/or colored overcoat onto the layer applied according to step Q) or onto the polysiloxane layer treated according to step T).

30. The method according to claim 29, further comprising: PP-QQ) applying at least one color layer onto at least one of the coatable surface of the metallic substrate, the metallic layer, the polysiloxane layer, the conversion layer, the treated polysiloxane layer according to step K) or L), the primer layer, or the treated polysiloxane layer according to step O) or P).

31. The method according to claim 29, wherein the metallic layer is applied in an average thickness in a range of 1 nm to 50 nm.

32. The method according to claim 31, wherein the metallic layer is applied in an average thickness in a range of 10 nm to 40 nm.

33. The method according to claim 32, wherein the metallic layer is applied in an average thickness in a range of 15 nm to 30 nm.

34. The method according to claim 29, wherein steps S) and T) are conducted prior to step U).

35. The method according to claim 30, wherein a layer according to step PP-QQ), a color polysiloxane layer, a color primer layer, or a color conversion layer is adjacent to and in contact with the layer applied according to step Q).

36. The method according to claim 26, wherein the steps D), M), N), P-Q), Q), S), T) and U) respectively follow each other.

37. The method according to claim 29, wherein the steps D), M), N), Q), S), T) and U) respectively follow each other.

38. The method according to claim 30, wherein the steps D), M), N), PP-QQ), Q), S), T) and U) respectively follow each other.

39. The method according to claim 26, wherein the steps D), M), N), O), P-Q), Q), S), T) and U) respectively follow each other.

40. The method according to claim 29, wherein the steps D), M), N), O), Q), S), T) and U) respectively follow each other.

41. The method according to claim 30, wherein the steps D), M), N), O), PP-QQ), Q), S), T) and U) respectively follow each other.

42. The method according to claim 26, wherein the steps D), E), F,), M), P-Q), Q), S), T) and U) respectively follow each other.

43. The method according to claim 29, wherein the steps D), E), F,), M), Q), S), T) and U) respectively follow each other.

44. The method according to claim 30, wherein the steps D), E), F,), M), PP-QQ), Q), S), T) and U) respectively follow each other.

45. The method according to claim 26, wherein the steps D), E), F,), M), O), P-Q), Q), S), T) and U) respectively follow each other.

46. The method according to claim 29, wherein the steps D), E), F,), M), O), Q), S), T) and U) respectively follow each other.

47. The method according to claim 30, wherein the steps D), E), F,), M), O), PP-QQ), Q), S), T) and U) respectively follow each other.

48. The method according to claim 26, wherein the steps D), G), H), M), P-Q), Q), S), T) and U) respectively follow each other.

49. The method according to claim 29, wherein the steps D), G), H), M), Q), S), T) and U) respectively follow each other.

50. The method according to claim 30, wherein the steps D), G), H), M), PP-QQ), Q), S), T) and U) respectively follow each other.

51. The method according to claim 26, wherein the step D), G), H), M), O), P-Q), Q), S), T) and U) respectively follow each other.

52. The method according to claim 29, wherein the steps D), G), H), M), O), Q), S), T) and U) respectively follow each other.

53. The method according to claim 30, wherein the steps D), G), H), M), O), PP-QQ), Q), S), T) and U) respectively follow each other.

54. The method according to claim 26, wherein the steps D), E), G), H), M), P-Q), Q), S), T) and U) respectively follow each other.

55. The method according to claim 29, wherein the steps D), E), G), H), M), Q), S), T) and U) respectively follow each other.

56. The method according to claim 30, wherein the steps D), E), G), H), M), PP-QQ), Q), S), T) and U) respectively follow each other.

57. The method according to claim 26, wherein the steps D), E), G), H), M), O), P-Q), Q), S), T) and U) respectively follow each other.

58. The method according to claim 29, wherein the steps D), E), G), H), M), O), Q), S), T) and U) respectively follow each other.

59. The method according to claim 30, wherein the steps D), E), G), H), M), O), PP-QQ), Q), S), T) and U) respectively follow each other.

60. The method according to claim 26, wherein the steps D), M), O), P-Q), Q), S), T) and U) respectively follow each other.

61. The method according to claim 29, wherein the steps D), M), O), Q), S), T) and U) respectively follow each other.

62. The method according to claim 30, wherein the steps D), M), PP-QQ), Q), S), T) and U) respectively follow each other.

63. The method according to claim 26, wherein the steps D), M), O), P-Q), Q), S), T) and U) respectively follow each other.

64. The method according to claim 29, wherein the steps D), M), O), Q), S), T) and U) respectively follow each other.

65. The method according to claim 30, wherein the steps D), M), O), PP-QQ), Q), S), T) and U) respectively follow each other.

66. The method according to claim 26, wherein the steps D), G), H), P-Q), Q), S), T) and U) respectively follow each other.

67. The method according to claim 29, wherein the steps D), G), H), Q), S), T) and U) respectively follow each other.

68. The method according to claim 30, wherein the steps D), G), H), PP-QQ), Q), S), T) and U) respectively follow each other.

69. The method according to claim 26, wherein the steps D), G), H), O), P-Q), Q), S), T) and U) respectively follow each other.

70. The method according to claim 29, wherein the steps D), G), H), O), Q), S), T) and U) respectively follow each other.

71. The method according to claim 30, wherein the steps D), G), H), O), PP-QQ), Q), S), T) and U) respectively follow each other.

72. A coated metallic substrate obtained according to the method of claim 26, wherein the coated metallic substrate comprises, in this order: a metallic substrate; a metallic layer that contains a second metal selected from the group consisting of titanium, hafnium and zirconium, or a second metal alloy selected from the group consisting of titanium, hafnium and zirconium alloys, and is plasma or corona-treated; a polysiloxane layer obtained by way of plasma polymerization of at least one organosilicon compound that is plasma or corona-treated; at least one conversion layer that is plasma or corona-treated; a polysiloxane layer obtained by way of plasma polymerization of at least one organosilicon compound that is plasma or corona-treated; at least one primer layer that is plasma or corona-treated; a polysiloxane layer obtained by way of plasma polymerization of at least one organosilicon compound that is plasma or corona-treated; at least one matt coating or at least one gloss coating; a metallic layer that contains a first metal selected from the group consisting of aluminum, silver, gold, lead, vanadium, manganese, magnesium, iron, cobalt, molybdenum, tungsten, nickel, copper, chromium, palladium, platinum, titanium, zirconium and zinc, or a first metal alloy selected from the group consisting of brass, bronze, steel, alloys of aluminum, magnesium and titanium, and is plasma or corona-treated; a polysiloxane layer obtained by way of plasma polymerization of at least one organosilicon compound that is plasma or corona-treated; and at least one transparent and/or colored overcoat that is applied onto the metallic layer that contains the first metal or first metal alloy or onto the outermost treated polysiloxane layer.

73. The coated metallic substrate according to claim 72, wherein the metallic layer adjacent to the overcoat is not transparent and not translucent for visible light.

74. A coated metallic substrate obtained according to the method of claim 29, wherein the coated metallic substrate comprises, in this order: a metallic substrate; a metallic layer that contains a second metal selected from the group consisting of titanium, hafnium and zirconium, or a second metal alloy selected from the group consisting of titanium, hafnium and zirconium alloys, and is plasma or corona-treated; a polysiloxane layer obtained by way of plasma polymerization of at least one organosilicon compound that is plasma or corona-treated; at least one conversion layer that is plasma or corona-treated; a polysiloxane layer obtained by way of plasma polymerization of at least one organosilicon compound that is plasma or corona-treated; at least one primer layer that is plasma or corona-treated; a polysiloxane layer obtained by way of plasma polymerization of at least one organosilicon compound that is plasma or corona-treated; a metallic layer that contains a first metal selected from the group consisting of aluminum, silver, gold, lead, vanadium, manganese, magnesium, iron, cobalt, molybdenum, tungsten, nickel, copper, chromium, palladium, platinum, titanium, zirconium and zinc, or a first metal alloy selected from the group consisting of brass, bronze, steel, alloys of aluminum, magnesium and titanium, which is plasma or corona-treated; a polysiloxane layer obtained by way of plasma polymerization of at least one organosilicon compound that is plasma or corona-treated; and at least one transparent and/or colored overcoat applied onto the treated polysiloxane layer that is adjacent to and covers the metallic layer containing the first metal or the first metal alloy.

75. The coated metallic substrate according to claim 74, further comprising at least one color layer that is plasma or corona-treated, and is adjacent to and covered by the metallic layer containing the first metal or first metal alloy.

76. The coated metallic substrate according to claim 74, wherein the metallic layer that contains the first metal or first metal alloy is transparent or is translucent for visible light.

77. The coated metallic substrate according to claim 74, wherein the metallic layer that contains the first metal or first metal alloy has an average thickness in a range of 1 nm to 50 nm,

78. The coated metallic substrate according to claim 77, wherein the metallic layer that contains the first metal or first metal alloy has an average thickness in a range of 10 nm to 40 nm,

79. The coated metallic substrate according to claim 78, wherein the metallic layer that contains the first metal or first metal alloy has an average thickness in a range of 15 nm to 30 nm.

80. The coated metallic substrate according to claim 75, wherein at least one color layer, a color polysiloxane layer, a color primer layer, or a color conversion layer is adjacent and in contact with the metallic layer containing the first metal or first metal alloy.

81. The coated metallic substrate according to claim 72, wherein the metallic substrate, the metallic layer containing the second metal or second metal alloy, a polysiloxane layer, the conversion layer, the primer layer, the matt or glossy coating, a color layer, and/or the overcoat, has a structured surface.

Description

[0297] The features of the invention disclosed in the foregoing description and in the claims can be essential for the implementation of the invention in its different embodiments, both individually as well as in any combination.