Method of coating a cast alloy wheel providing a two-tone appearance

Abstract

A cast wheel having an alloy substrate includes a primary surface and a secondary surface. A first polymeric coating is applied to the primary surface and to the secondary surface sealing the cast alloy wheel within the first polymeric coating. An intermediate polymeric coating is applied over the first polymeric coating. The intermediate polymeric coating is coated with metal using physical vapor deposition with the metal being aesthetically distinguishable from the first polymeric coating. A third polymeric coating is applied over the metal. The third polymeric coating, the intermediate coating and the metal from the primary surface of the cast alloy wheel are removed aesthetically distinguishing the primary surface from the secondary surface. A fourth polymeric coating is applied over the primary surface and the secondary surface.

1 . A method of coating a cast alloy wheel, comprising the steps of:
 providing a cast wheel having an alloy substrate including a primary surface and a secondary surface;   applying a first polymeric coating being pigmented to said primary surface and to said secondary surface thereby sealing said cast alloy wheel within said first polymeric coating;   coating the first polymeric coating with metal using vapor deposition with said metal being aesthetically distinguishable from said first polymeric coating;   applying a second polymeric coating over said metal;   removing said second polymeric coating and said metal from said primary surface of said cast alloy thereby exposing at least a portion of the first polymeric coating providing aesthetically distinguishing appearance of said first polymeric coating disposed upon said primary surface from said metal disposed upon said secondary surface; and   applying a third polymeric coating over said primary surface and said secondary surface.   
     
     
         2 . The method set forth in  claim 1 , further including a step of applying an intermediate polymer coating over said first polymer coating that is pigmented for being aesthetically distinguishable from said metal and from said first polymer coating and removing a portion of said intermediate coating at said primary surface thereby leaving a visible bead of said intermediate coating adjacent an edge of said metal. 
     
     
         3 . The method set forth in  claim 1 , wherein said step of applying a third polymeric coating over said primary surface and said secondary surface is further defined by applying a clear third polymeric coating. 
     
     
         4 . The method set forth in  claim 1 , wherein said step of applying a third polymeric coating over said primary surface and said secondary surface is further defined by applying a pigmented third polymeric coating and defining a visible bead of said first polymeric coating between said alloy substrate and said metal. 
     
     
         5 . The method set forth in  claim 1 , further including a step of removing a portion said second polymeric coating at said primary surface thereby exposing said first polymeric coating while leaving a visible bead of said second polymeric coating between said first polymeric coating and an edge of said metal. 
     
     
         6 . The method set forth in claim I, wherein said step of removing said second polymeric: coating and said metal at said primary surface is further defined by removing a portion of said first polymeric coating thereby creating an aesthetic contrast between said metal and said first polymeric coating. 
     
     
         7 . The method set forth in  claim 1 , further including the step of removing said first polymeric coating thereby exposing said alloy substrate for creating an aesthetic contrast between said metal and said alloy substrate. 
     
     
         8 . The method set forth in  claim 7 , further including a step of applying a clear polymeric coating over said substrate and said second polymeric coating. 
     
     
         9 . The method set forth in  claim 1 , further including a step of applying an intermediate polymeric coating between said metal and said second polymeric coating, wherein said intermediate polymeric coating includes a higher gloss level than does the first polymeric coating and removing said metal and a portion of said intermediate coating thereby leaving a bead of said intermediate polymeric coating visible between said metal and said second polymeric coating. 
     
     
         10 . The method set forth in  claim 9 , wherein said step of applying a said intermediate polymeric coating is further defined by said intermediate polymeric coating being one of a clear polymeric coating, a pigmented polymeric coating distinguishable from said first polymeric coating, or a pigmented polymeric coating being indistinguishable from said first polymeric coating. 
     
     
         11 . (canceled) 
     
     
         12 . (canceled) 
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . (canceled) 
     
     
         17 . (canceled) 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . (canceled)