Multi-layer anti-corrosive coating

Abstract

A multilayer coating has a first coating layer deposited on a substrate; a second coating layer deposited on the first coating layer; and a third coating layer deposited on the second coating layer. The first coating layer is substantially a metal, the second coating layer is a mixture of the metal and a polymeric material, and the third coating layer is substantially the polymeric material. The substrate is at least one of iron, iron pipe, steel, copper, nickel, concrete, wood, wood products, fiberglass, ceramic, plastic, and any other metal or non-metal material that can be used as a substrate, and the metal is at least one of zinc, aluminum, magnesium, indium, gallium, tellurium, and alloys thereof, whereby the metal used is anodic to the substrate. The polymeric material is at least one of polyethylene, polypropylene, nylon, polytetrafluorethylene (PTFE), ethylene methacrylate acid copolymer (EMAA), a thermoplastic material and a thermoset material.

1 . A multilayer coating comprising:
 a first coating layer on a substrate;   a second coating layer deposited on the first coating layer; and   a third coating layer deposited on the second coating layer;   wherein the first coating layer is substantially a metal, the second coating layer is a mixture of the metal and a polymeric material, and the third coating layer is substantially the polymeric material.   
     
     
         2 . The multilayer coating of  claim 1 , wherein the substrate comprises at least one of iron, iron pipe, alloys of iron, steel, copper, alloys of copper, nickel, alloys of nickel, concrete, wood, wood products, fiberglass, ceramic and plastic. 
     
     
         3 . The multilayer coating of  claim 1 , wherein the metal comprises at least one of zinc, aluminum, alloy of zinc-aluminum, magnesium, alloy of zinc-magnesium, alloy of aluminum-magnesium, indium, alloy of zinc-indium, alloy of aluminum-indium, alloy of magnesium-indium, gallium, alloy of zinc-gallium, alloy of aluminum-gallium, alloy of magnesium-gallium, alloy if indium-gallium, tellurium, alloy of zinc-tellurian, alloy of aluminum-tellurium, alloy of magnesium-tellurium, alloy of indium-tellurium, and alloy of gallium-tellurium. 
     
     
         4 . The multilayer coating of  claim 3 , wherein the zinc is at least 99% zinc. 
     
     
         5 . The multilayer coating of  claim 3 , wherein the aluminum-zinc ratio is about 85% aluminum to about 15% zinc. 
     
     
         6 . The multilayer coating of  claim 1 , wherein the substrate is a metallic material, and wherein the metal is anodic to the substrate. 
     
     
         7 . The multilayer coating of  claim 1 , wherein the polymeric material comprises at least one of polyethylene, polypropylene, nylon, polytetrafluorethylene (PTFE), ethylene methacrylate acid copolymer (EMAA), a thermoplastic material and a thermoset material. 
     
     
         8 . The multilayer coating of  claim 7 , wherein the thermoset material is a fusion bonded epoxy. 
     
     
         9 . The multilayer material of  claim 1 , wherein a first thickness of the first coating layer is approximately 25 microns to approximately 200 microns. 
     
     
         10 . The multilayer material of  claim 1 , wherein a first thickness of the first coating layer is approximately 50 microns to approximately 100 microns. 
     
     
         11 . The multilayer material of  claim 1 , wherein a second thickness of the second coating layer is approximately 5 microns to approximately 200 microns. 
     
     
         12 . The multilayer material of  claim 1 , wherein a second thickness of the second coating layer is approximately 5 microns to approximately 100 microns. 
     
     
         13 . The multilayer material of  claim 1 , wherein a third thickness of the third coating layer is approximately 5 microns to approximately 200 microns. 
     
     
         14 . The multilayer material of  claim 1 , wherein a third thickness of the third coating layer is approximately 50 microns to approximately 150 microns. 
     
     
         15 . The multilayer coating of  claim 1 , wherein the multilayer coating forms a corrosion resistant coating. 
     
     
         16 . A multilayer coating comprising:
 a first coating layer deposited on a substrate;   a second coating layer deposited on the first coating layer; and   a third coating layer deposited on the second coating layer;   wherein the first coating layer is substantially a metal, the second coating layer is a mixture of the metal and a polymeric material, and the third coating layer is substantially the polymeric material;   wherein the substrate comprises at least one of iron, iron pipe, alloys of iron, steel, copper, alloys of copper, nickel, alloys of nickel, concrete, wood, wood products, fiberglass, ceramic and plastic;   wherein the metal comprises at least one of zinc, aluminum, alloy of zinc-aluminum, magnesium, alloy of zinc-magnesium, alloy of aluminum-magnesium, indium, alloy of zinc-indium, alloy of aluminum-indium, alloy of magnesium-indium, gallium, alloy of zinc-gallium, alloy of aluminum-gallium, alloy of magnesium-gallium, alloy if indium-gallium, tellurium, alloy of zinc-tellurian, alloy of aluminum-tellurium, alloy of magnesium-tellurium, alloy of indium-tellurium, and alloy of gallium-tellurium;   wherein when the substrate comprises a metallic material, and wherein the metal is anodic to the substrate;   wherein the polymeric material comprises at least one of polyethylene, polypropylene, nylon, polytetrafluorethylene (PTFE), ethylene methacrylate acid copolymer (EMAA), a thermoplastic material and a thermoset material;   wherein a first thickness of the first coating layer is approximately 25 microns to approximately 200 microns;   wherein a second thickness of the second coating layer is approximately 5 microns to approximately 200 microns; and   wherein a third thickness of the third coating layer is approximately 5 microns to approximately 200 microns.   
     
     
         17 . A method of providing a multilayer coating comprising:
 applying a first coating layer on a substrate;   applying a second coating layer on the first coating layer; and   applying a third coating layer on the second coating layer;   wherein the first coating layer is substantially a metal, the second coating layer is a mixture of the metal and a polymeric material, and the third coating layer is substantially the polymeric material.   
     
     
         18 . The method of providing the multilayer coating of  claim 17 , wherein the first coating layer, the second coating layer and the third coating layer are applied sequentially using at least one of cold spray, thermal spray and plasma spray. 
     
     
         19 . The method of providing the multilayer coating of  claim 17 , further comprising the step of heating the substrate to approximately the fusion temperature of the metal when applying the first coating layer. 
     
     
         20 . The method of providing the multilayer coating of  claim 17 , further comprising the step of heating the substrate to approximately the fusion temperature of the polymeric material when applying the third coating layer.