Methods of forming polymer coatings on metallic substrates

1. An article comprising

a substrate comprising a metal or an alloy of the metal, the metal comprising one or more of the following: magnesium; aluminum; titanium; manganese; iron; cobalt; nickel; copper; molybdenum; tungsten; palladium; chromium; ruthenium; gold; silver; zinc; zirconium; vanadium; or silicon;

a polymer coating; and

an intermediate layer disposed between the substrate and the polymer coating, the intermediate layer comprising a carbon composite,

the carbon composite comprising carbon and a binder containing one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal of the carbon composite; or an alloy of the metal; and

the metal of the carbon composite comprising one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium,

wherein the article further comprises a first binding layer directly disposed on the substrate and between the intermediate layer and the substrate, the first binding layer comprising one or more of the following: a solid solution of the metal in the substrate and the binder in the carbon composite; a solder; or a reaction product of a thermite composition comprising a reducing agent and an oxidization agent; and

the article further comprises a second binding layer between the polymer coating and the intermediate layer, the second binding layer comprising a first polymer, a monomer or a combination thereof, the first polymer and the monomer being bonded to the carbon in the carbon composite of the intermediate layer through covalent bonding.

2. The article of claim 1 , wherein the polymer coating comprises one or more of the following: a fluoroelastomer; a perfluoroelastomer, hydrogenated nitrile butyl rubber; ethylene-propylene-diene monomer (EPDM) rubber; a silicone; an epoxy; polyetheretherketone; bismaleimide; polyethylene; a polyvinylalcohol; a phenolic resin; a nylon; a polycarbonate; a polyurethane; a tetrafluoroethylene-propylene elastomeric copolymer; polyphenylene sulfide; polyphenylsulfone; self-reinforced polyphenylene; a polyaryletherketone; or a crosslinked product thereof.

3. The article of claim 1 , wherein the carbon in the carbon composite comprises graphite.

4. The article of claim 3 , wherein the graphite is derivatized to have one or more of the following functional groups: carboxy; epoxy; ether; ketone; amine; hydroxy; alkoxy; alkyl; lactone; or aryl.

5. The article of claim 1 , wherein the second binding layer between the polymer coating and the intermediate layer comprises the first polymer; and the first polymer comprises one or more of the following: an acrylic chain; a polyamine; or a poly(alkylene glycol).

6. The article of claim 1 , wherein the second binding layer between the polymer coating and the intermediate layer comprises the monomer; and the monomer comprises one or more of the following polymerizable groups: an α,β-unsaturated nitrile group; alkenyl group; alkynyl group; vinyl carboxylate ester group; carboxyl group; carbonyl group; epoxy group; isocyanate group; hydroxyl group; amide group; amino group; ester group; formyl group; nitrile group; or nitro group.

7. The article of claim 1 , wherein the polymer coating has a thickness of about 5 μm to about 10 mm.

8. The article of claim 1 , wherein the carbon composite comprises carbon microstructures having interstitial spaces among the carbon microstructures, wherein the binder is disposed in at least some of the interstitial spaces.

9. The article of claim 8 , wherein the carbon microstructures comprise unfilled voids within the carbon microstructures.

10. The article of claim 8 , wherein the binder or a derivative thereof is disposed in the voids within the carbon microstructures.

11. The article of claim 1 , wherein the first binding layer comprises the solder.

12. The article of claim 1 , wherein the first binding layer comprises the reaction product of the thermite composition, the reducing agent comprising aluminum, magnesium, calcium, titanium, zinc, silicon, boron, and combinations including at least one of the foregoing, and the oxidizing agent comprising boron oxide, silicon oxide, chromium oxide, manganese oxide, iron oxide, copper oxide, lead oxide and combinations including at least one of the foregoing.

13. A method of coating a substrate to form the article of claim 1 , the method comprising:

disposing the intermediate layer on the substrate;

binding the intermediate layer to the substrate forming the first binding layer directly on the substrate and between the intermediate layer and the substrate, the first binding layer comprising one or more of the following: the solid solution of the metal in the substrate and the binder in the carbon composite; the solder; or the reaction product of the thermite composition comprising the reducing agent and the oxidization agent;

grafting the monomer, the first polymer, or the combination thereof on the intermediate layer disposed on the substrate to provide the second binding layer, the first polymer and the monomer being bonded to the carbon in the intermediate layer through covalent bonding; and

coating the second binding layer with a coating composition comprising a second polymer forming the polymer coating;

wherein the intermediate layer comprises carbon and the binder;

the binder comprises one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal of the carbon composite; or the alloy of the metal; and

the metal of the carbon composite comprises one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium.

14. The method of claim 13 , wherein coating the second binding layer comprises one or more of the following: lamination; dip coating; solvent casting; painting; spraying coating; roll coating; layer-by-layer coating; spin coating; or Langmuir-Blodgett coating.

15. The method of claim 13 , wherein the coating composition further comprises a crosslinker.

16. The method of claim 13 , wherein the method further comprises crosslinking the first polymer with the second polymer.

17. The method of claim 13 , wherein binding the intermediate layer to the substrate comprises heating the intermediate layer and the substrate to form the first binding layer between the intermediate layer and the substrate; wherein optionally the intermediate layer and the substrate are pressed together during heating.

18. The method of claim 13 , wherein binding the intermediate layer to the substrate comprises heating the intermediate layer and a surface of the substrate that the intermediate layer is disposed on by one or more of the following: direct current heating; induction heating; microwave heating; or spark plasma sintering; wherein optionally the intermediate layer and the substrate are pressed together during heating.

19. The method of claim 13 , wherein the method further comprises disposing the solder between the intermediate layer and the substrate; applying heat to the solder; and binding the intermediate layer to the substrate thereby forming the first binding layer; wherein optionally the intermediate layer and the substrate are pressed together while applying heat to the solder.

20. The method of claim 13 , wherein the reducing agent comprises one or more of the following: aluminum; magnesium; calcium; titanium; zinc; silicon; or boron; and the oxidizing agent comprises one or more of the following: boron oxide; silicon oxide; chromium oxide; manganese oxide; iron oxide; copper oxide; or lead oxide.

21. An article comprising

a substrate comprising a metal or an alloy of the metal, the metal comprising one or more of the following: magnesium; aluminum; titanium; manganese; iron; cobalt; nickel; copper; molybdenum; tungsten; palladium; chromium; ruthenium; gold; silver; zinc; zirconium; vanadium; or silicon;

a polymer coating; and

an intermediate layer disposed between the substrate and the polymer coating, the intermediate layer comprising a carbon composite,

the carbon composite comprising carbon and a binder containing one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal of the carbon composite; or an alloy of the metal; and

wherein the metal of the carbon composite comprises one or more of the following: aluminum; copper; titanium; tungsten; chromium; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium,

wherein the article further comprises a first binding layer directly disposed on the substrate and between the intermediate layer and the substrate; the first binding layer comprising one or more of the following: a solid solution of the metal of the substrate and the binder in the carbon composite; a solder; or a reaction product of a thermite composition comprising a reducing agent and an oxidization agent, and

the article further comprises a second binding layer between the polymer coating and the intermediate layer, the second binding layer comprising a first polymer or a monomer, the first polymer and the monomer being bonded to the carbon in the carbon composite of the intermediate layer through covalent bonding.