CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S. Provisional Application No.
62/614,385, filed on January 6, 2018, the entire disclosure of which is hereby incorporated by
reference herein.
BACKGROUND
[0002] The present application relates to multi-colored finishes for fixtures, and fixtures having
such finishes. More specifically, disclosed herein are methods of applying such finishes to
achieve a surface appearance that transitions in color, shade, or lightness from one region to
another, typically in a graduated fashion.
SUMMARY
[0003] At least one embodiment relates to a method of applying a multi-color finish to a
plumbing fixture that includes depositing a first coating on the plumbing fixture; selectively
applying a masking material in a graduated fashion over at least a portion of the first coating to
define a gradient from a first portion of the plumbing fixture that is substantially completely
covered by the masking material to a second portion of the plumbing fixture that has
substantially no masking material; depositing a second coating over the masking material; and
removing the masking material from the plumbing fixture such that the plumbing fixture has a
surface finish including a transition region representing a gradual transition between the first
coating and the second coating.
[0004] In some exemplary embodiments, the transition region includes a first percentage of the
first coating and a second percentage of the second coating.
[0005] In some exemplary embodiments, the first percentage is in a range of about 5% to about
95% with the remaining balance as the second percentage.
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[0006] In some exemplary embodiments, the transition region includes a plurality of
percentages of the first coating and a plurality of percentages of the second coating.
[0007] In some exemplary embodiments, the first coating defines a first finish having a first
appearance and the second coating defines a second finish having a second appearance that is
different from the first appearance.
[0008] In some exemplary embodiments, the first finish and the second finish are selected from
at least one of polished chrome, brushed chrome, polished French gold, polished titanium,
brushed titanium, polished rose gold, polished modern gold, polished tungsten, polished modern
brass, satin titanium, polished satin chrome, satin bronze, polished brass, satin brass, oil-rubbed
bronze, polished nickel, brushed nickel, or matte black.
[0009] In some exemplary embodiments, the step of depositing the first coating and the step of
depositing the second coating are conducted using at least one of physical vapor deposition
(PVD), chemical vapor deposition (CVD), atomic layer deposition (ALD), electroplating, dip
coating, or spray coating.
[0010] In some exemplary embodiments, the step of depositing the first coating and the step of
depositing the second coating are each conducted using physical vapor deposition (PVD), and
wherein the PVD is conducted as the plumbing fixture is rotated on a turntable.
[0011] In some exemplary embodiments, the PVD is selected from at least one of cathodic-arc
evaporation, sputter deposition, or high-impulse power magnetron sputtering (HIPIMS).
[0012] In some exemplary embodiments, the masking material includes at least one of
molybdenum disulfide, tungsten disulfide, boron nitride, or graphite.
[0013] In some exemplary embodiments, after the step of masking, the masking material is
cured at a temperature in a range of about 60°C to about 250°C for a time in a range of about 15
minutes to about 120 minutes.
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[0014] In some exemplary embodiments, the masking material is applied by a technique
selected from the group consisting of printing, powder coating, painting, spraying, dipping,
brushing, and dry-powder tumbling.
[0015] In some exemplary embodiments, the masking material is applied by spraying, and the
spraying is conducted as the plumbing fixture is rotated on a turntable.
[0016] In some exemplary embodiments, the step of depositing the second coating comprises
depositing the second coating on the first portion and the second portion.
[0017] In some exemplary embodiments, the step of removing the masking material comprises
washing the plumbing fixture using at least one of a water-based wash, an acid wash, or an
organic solvent-based wash.
[0018] Another exemplary embodiment relates to a multi-color plumbing fixture including a
surface finish. The surface finish includes a first appearance, a second appearance, and a
transition region. The first appearance is on a first portion of the plumbing fixture. The second
appearance is on a second portion of the plumbing fixture, wherein the second appearance is
different from the first appearance. The transition region is disposed between the first portion
and the second portion, wherein the transition region represents a gradual transition between the
first appearance and the second appearance.
[0019] In some exemplary embodiments, the first appearance is defined by a first coating, and
wherein the second appearance is defined by a masking material.
[0020] In some exemplary embodiments, the first appearance is defined by a first coating
having a first finish, and wherein the second appearance is defined by a second coating having a
second finish that is different from the first finish.
[0021] In some exemplary embodiments, the transition region includes a first percentage of the
first coating and a second percentage of the second coating.
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[0022] In some exemplary embodiments, the transition region includes a plurality of
percentages of the first coating and a plurality of percentages of the second coating.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a flow diagram illustrating a method of applying a multi-color finish to a
fixture according to an exemplary embodiment.
[0024] FIG. 2 illustrates a plumbing fixture including a masking material and a first coating
according to an exemplary embodiment.
[0025] FIG. 3 is illustrates a plumbing fixture including a masking material and a first coating
according to another exemplary embodiment.
[0026] FIG. 4 illustrates a faucet plumbing fixture having a final ombré appearance according
to an exemplary embodiment.
[0027] FIG. 5 illustrates a process for masking a portion of a plumbing fixture, according to an
exemplary embodiment.
[0028] FIG. 6 illustrates a mask-less configuration for depositing a coating in a vacuum
chamber, according to another exemplary embodiment.
[0029] FIG. 7 illustrates a mask-less configuration for depositing a coating in a vacuum
chamber, according to another exemplary embodiment.
DETAILED DESCRIPTION
[0030] In the following detailed description, reference is made to the accompanying drawings,
which form a part hereof. In the drawings, similar symbols typically identify similar
components, unless context dictates otherwise. The illustrative embodiments described in the
detailed description, drawings, and claims are not meant to be limiting. Other embodiments may
be utilized, and other changes may be made, without departing from the spirit or scope of the
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subject matter presented here. It will be readily understood that the aspects of the present
disclosure, as generally described herein, and illustrated in the figures, can be arranged,
substituted, combined, and designed in a wide variety of different configurations, all of which
are explicitly contemplated and made part of this disclosure.
[0031] As used in the present disclosure, the term “ombré” may be used to describe a visual
effect in which a color, shade, or lightness gradually transitions from one region to another. For
example, a color may be graduated from darker to lighter from one region to the next. The actual
graduation may be from a darker color to a lighter color, from one shade to another, or to any
combination of colors or shades. While ombré effects have been used most frequently in the
textile and hair industries, they have not been adapted for use in connection with surfaces having
irregular patterns or shapes, and specifically for plumbing fixtures that require a resilient finish
that is intended to withstand ordinary usage in such environments.
[0032] It would be advantageous to provide a novel method for applying multi-color finishes to
fixtures, and to produce products employing such finishes to provide a unique and heretofore
unused finish for such products. These and other advantageous features will be apparent to those
reviewing the present disclosure.
[0033] The present disclosure provides for a method of forming a multicolor finish to a fixture,
and fixtures having such finish. Referring to the exemplary embodiment of FIG. 1, a first step
100 of the disclosed process includes providing a fixture, shown as a plumbing fixture 10, as a
substrate upon which the multicolor finish will be applied. The plumbing fixture is not meant to
be limited and may be any household plumbing fixture associated with delivering and draining
water. The plumbing fixture may be at least one of faucets for sinks, tubs, whirlpools, shower
heads, spas, soap dispensers, and the like; faucet handles; faucet accessories such as fluid
conduits (e.g., water piping, hoses, etc.); or water containers or vessels such as sinks, tubs,
whirlpools, spas, etc. In another embodiment, the multicolor finish may also be applied to other
fixtures, such as bathroom or kitchen fixtures such as towel holders, lighting fixtures, or
ventilation fixtures. Moreover, the surface finish may be applied to a surface of the fixture that
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is made from at least one of a low-corrosive metal or metal alloys (e.g., tungsten, titanium,
chrome, pewter, copper, bronze, brass, stainless steel, zinc alloys), ceramic (e.g., porcelain),
glass, plastic, or combinations thereof.
[0034] A second step 200 of the process according to the embodiment of FIG. 1 includes
depositing a first coating 20 on the plumbing fixture 10 to obtain a first finish having a first
appearance. In one embodiment, the step of depositing the first coating includes depositing the
first coating on the entire surface area of the plumbing fixture. In another embodiment, only a
portion of the surface area of the fixture is coated with the first finish. The first finish may be at
least one of a polished metal, brushed metal, gold-plated, oil-rubbed metal, satin metals or
combinations thereof. Non-limiting examples of the first finish include polished chrome,
brushed chrome, polished French gold, polished titanium, brushed titanium, polished rose gold,
polished modern gold, polished tungsten, polished modern brass, satin titanium, polished satin
chrome, satin bronze, polished brass, satin brass, oil-rubbed bronze, polished nickel, brushed
nickel, matte black, and the like.
[0035] The step of depositing the first coating may be conducted using at least one of a vacuum
deposition (physical vapor deposition, PVD; chemical vapor deposition, CVD; atomic layer
deposition, ALD), electroplating, dip coating, or spray coating process. In one embodiment,
PVD is used as the deposition technique for forming the first coating on the plumbing fixture.
[0036] PVD vacuum deposition processes are advantageous because they involve no aqueous
component and are more environmentally friendly and economical than wet chemical processes.
PVD coatings are typically harder and more corrosion-resistant than coatings applied by
electroplating. Most PVD coatings have high temperature and good impact strength, excellent
abrasion resistance, and are durable such that protective topcoats are optional. PVD deposition
processes include at least one of cathodic arc evaporation, electron beam (e-beam) PVD,
evaporative deposition, pulsed-laser deposition, sputter deposition, ion plating, or pulsedelectron
deposition. In typical PVD processes, a material is vaporized from a solid source and
transported in a vacuum environment as a vapor to a substrate where it condenses, forming a
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coating. The vacuum environment is configured such that the mean free path for collision
between particles is on the order of the dimensions of the processing chamber or through a lowpressure
environment of gas or plasma (ionized gas).
[0037] In some embodiments, the PVD process of the first coating is a reactive deposition
process whereby the depositing species reacts with a gas species in the processing environment
to form a compound prior to depositing (e.g., nitrogen reacting with depositing titanium to form
a coating of TiN (having a gold appearance)). Decorative/wear PVD coatings for plumbing
fixtures include TiN (having a gold appearance), ZrN (having a brass-like appearance), TiC
(having a black appearance), TICN (having an “anthracite gray” appearance), ZrCN (having a
nickel-like appearance), ZrCrCN (having a brass-like appearance), and ZrCrN (having a gold or
rose-gold appearance). In one embodiment, a thickness of the first coating may vary in a range
of about 100 nm to about 2000 nm. In some embodiments, prior to PVD deposition, at least one
thin seed or primer layer may be deposited on the plumbing fixture to achieve enhanced bonding
characteristics with the subsequently PVD coating. For surfaces that are non-planar, the
plumbing fixture may be set on a turntable that manually or automatically rotates as the first
coating is applied.
[0038] In some embodiments, the vacuum deposition of the first coating is conducted using
vacuum evaporation, whereby an evaporation material source is thermally vaporized from a
container heated either electrically or by an e-beam. The vaporization is conducted such that the
trajectory of the vaporized material is line-of-sight. The vacuum environment reduces
contamination from the deposition environment. Typical gas pressures are in a range of 10-5 Torr
to 10-6 Torr. In other embodiments, the vacuum deposition is conducted using sputter
deposition, whereby atoms are removed from a solid “target” of the to-be-deposited material by
bombardment with accelerated ions. Momentum transfer causes ejection of surface atoms,
which are then deposited onto the substrate. Sputtering occurs at less than 5 × 10-3 Torr where
particles do not suffer from collisions with gas molecules in the volume between the target and
substrate. Sputter deposition includes diode, magnetron and ion beam sputtering.
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[0039] In yet other embodiments, the vacuum deposition is conducted using high-impulse
power magnetron sputtering (HIPIMS), whereby short pulses of high power are applied to the
target on the order of kW/cm2. At these power levels, ionization of the sputtered material creates
a metal-based plasma. Coatings made by HIPIMS are very dense and smooth in character. In
yet other embodiments, the vacuum deposition is conducted using ion plating using energetic ion
bombardment during deposition to densify the deposit and control properties of the coating such
as stress and microstructure. Ion bombardment during deposition is conducted by accelerating
ions from a plasma directly to the solid material source or by using a separate ion source (e.g.,
“ion gun”).
[0040] A third step 300 of the process according to the embodiment of FIG. 1 includes
masking 30 a portion of the plumbing fixture 10. In general, the step of masking is conducted to
selectively protect a portion of the plumbing fixture 10 that already comprises the first coating
20. The masking 30 may define a second appearance of the plumbing fixture 10 that is different
from the first appearance of the first coating. In a subsequent deposition process (i.e., step 400
of FIG. 1), a second coating is deposited directly on both the protected and unprotected portions
of the plumbing fixture to define a second finish having a second appearance different from the
first appearance. Therefore, selection of the mask material is based on its ability to selectively
separate in a post-deposition wash (i.e., step 500 of FIG. 1), carrying with it the portion of the
second coating deposited on the mask while leaving the portion of the first coating deposited
underneath the mask intact. Moreover, another factor in selecting the mask material is its
outgassing properties. Similar to the methods of forming the first coating, in some embodiments,
the second coating is also deposited in a vacuum environment. In vacuum environments, one
common problem is the release of gas from the bulk of a material positioned in the vacuum
chamber. This outgassing adds to the pressure load in the chamber and affects film deposition
rates and introduces contamination into the deposited film. For example, for masking materials
having a high outgassing rate would potentially result in contamination of the second coating
with outgassed elements (adversely affecting the aesthetics of the resultant film), as well as
reduce deposition rates of the second coating due to decreased mean free path for collision
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between the depositing material and other gaseous particles between the target and substrate.
Therefore, to minimize contamination and reduce deposition rates of the second coating,
Applicant advantageously utilized a masking material having a low outgassing rate.
[0041] Vacuum-compatible masking materials may be selected from at least one of metals,
plastics, glasses, ceramics, lubricants, or adhesives. Non-limiting examples of metal masks
include: austenitic stainless steels, mild steels, aluminum and aluminum alloys, aluminum
bronze, nickel and nickel alloys, beryllium, oxygen-free copper, indium, gold, platinum,
zirconium, titanium, tungsten, molybdenum, tantalum, niobium, and solders (e.g., tin-silver
eutectic (95% Sn, 5% Ag)). Non-limiting examples of plastic masks include: fluoropolymers
(e.g., polyvinylidene fluoride, polytetrafluoroethylene), vespel polyimide, polycarbonates,
polystyrene, polyetheretherketone (PEEK), Kapton, and elastomers (e.g., nitrile rubber,
fluorinated elastomers, perfluoroelastomeric compounds). Non-limiting examples of glasses and
ceramics include: borosilicate glass, alumina ceramics, and fluorphlogopite mica in borosilicate
glass matrices. Non-limiting examples of lubricants include vacuum greases (e.g., Ramsey
grease, fluorether-based greases, polyphenyl ether greases) and dry lubricants (e.g., molybdenum
disulfide, tungsten disulfide, boron nitride, graphite), which are materials that, despite being in
the solid phase, effectively reduces friction between two in-contact surfaces without needing a
liquid oil medium. In one embodiment, the vacuum-compatible masking material is a mixture
comprising boron nitride.
[0042] In one embodiment, the vacuum-compatible masking material is a dry lubricant
fabricated by a method selected from the group consisting of printing, powder coating, painting,
spraying, dipping, brushing, and dry-powder tumbling. For example, a dry lubricant material is
initially dispersed as an additive in a solvent such as an organic solvent, water, or grease. The
substrate (e.g., plumbing fixture) may then be selectively spray-coated with the additivecontaining
solvent and then allowed to cure until the solvent evaporates, leaving behind a solid,
dry lubricant. In one embodiment, a thickness of the masking material may greater than the
thickness of either the first coating or second coating, for example, in a range of about 10 μm to
about 100 μm. In one embodiment where boron nitride is used as the masking material, the
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curing is conducted at a range of about 60°C to about 250°C (e.g., 80°C) for a time in a range of
about 15 minutes to about 120 minutes (e.g., 20 minutes) for each layer.
[0043] For surfaces that are non-planar, the plumbing fixture may be set on a turntable that
manually or automatically rotates 360° as the masking material is applied. The material is
sprayed in any desired predetermined pattern, but in a graduated fashion to define a gradient.
For example, as seen in the embodiment of FIG. 2, one end of the plumbing fixture 202 may be
substantially completely (i.e., about 100%) covered with the masking material 204 with a
gradient forming as the spray coating is applied further and further away from the 100%-coated
end until the fixture 202 has substantially no (i.e., about 0%) mask applied over the first coating
206 (i.e., the first coating is mostly visible). In another exemplary embodiment shown in FIG. 3,
a middle portion of the plumbing fixture 302 is substantially completely covered with the
masking material 304 with a gradient forming as the spray coating is applied further and further
away in each direction from the substantially100%-coated middle portion until the fixture 302
has substantially no mask applied over the first coating 306. It should be noted that any desired
pattern for the masking material may be employed according to various exemplary embodiments.
[0044] FIG. 5 illustrates a process for masking a portion of the plumbing fixture, according to
an exemplary embodiment. A plumbing fixture 500 is positioned atop a rotatable turntable 502
and temporarily affixed to a centrally located rod 504 extending upwards from a top surface of
the turntable. The fixture 500 may be affixed to the rod 504 using any fastening arrangement,
such as a clip, pin, adhesive, etc., such that when rotated, the fixture remains secure to achieve a
predetermined patterning of the masking material 508, which is sprayed using a spray gun 506
(e.g., a pressurized container, etc.). The rod 504 may be modified depending on the type of
fixture upon which the masking material 508 is being deposited. For example, an extension
length and/or width of the rod may be altered depending on the dimensions of the fixture to
maximize stability of the fixture while rotated.
[0045] In some exemplary embodiments, the spray gun 506 is manually held by a user
applying the masking material 508. In other exemplary embodiments, the spray gun 506 is held
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by a robotic arm as the turntable 502 rotates. The turntable rotates at predetermined revolutions
per minute in a range of about 5 rpm to about 15 rpm. In one example, the turntable may rotate
at about 10 rpm. The spray gun 506, whether held manually or by robotic arm, is positioned at a
distance in a range of about 6 inches to about 24 inches away from the rotating fixture. In one
example, the spray gun may be held at a distance of about 12 inches away from the rotating
fixture. It is also contemplated that the spray gun 506, whether held manually or by robotic arm,
is rotated around the fixture 500, with the fixture being stationary. As the masking material 508
is sprayed onto the fixture target, the intensity of the spray stream varies along the angle at which
it exits the spray gun 506. In other words, the portion of the fixture 500 which experiences the
center of the spray stream will have a greater density of masking material coated thereon (i.e.,
more complete coverage) than will the portion of the fixture 500 which experiences an edge of
the spray stream (i.e., less complete coverage). FIG. 5 depicts this phenomena using the dashed
lines for the masking material 508 exiting the spray gun 506.
[0046] The spray gun 506 may be moved linearly up and down along a length of the fixture to
achieve the desired coverage such that below a certain length of the fixture (e.g., below a
position ‘a’) to where the fixture meets a top surface of the turntable 502, there is substantially
complete (e.g., about 100%) coverage of the masking material on the fixture. Above the position
‘a’ is the portion of the fixture, which has a gradient of masking material coated thereon.
Rotation is continued until a predetermined masking material pattern is achieved.
[0047] A fourth step 400 of the process according to the embodiment of FIG. 1 includes
depositing a second coating 40 on the plumbing fixture 10 atop both the protected portion coated
with the masking material 30 and the unprotected portion coated by only the first coating 20. In
one embodiment, a thickness of the second coating may vary in a range of about 100 nm to about
2000 nm. As described above, the second coating may be deposited using a deposition
technique, which is the same as or different from the deposition technique used for fabricating
the first coating.
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[0048] A fifth step 500 of the process according to the embodiment of FIG. 1 includes
removing the mask 30 from the plumbing fixture 10 to achieve a final ombré appearance (i.e., a
dual-coated, graded appearance) whereby the fixture 10 comprises the first coating 20 having a
first appearance, the second coating 40 having a second appearance different from the first
appearance, and a transition region 50 representing the gradual transition of the first coating 20
to the second coating 40, or vice-versa. In one exemplary embodiment, the transition region 50
includes a first percentage of the first coating and a second percentage of the second coating.
The first percentage is in the range of about 5% to about 95%, with the remaining balance as the
second percentage. In one exemplary embodiment, the transition region 50 includes a plurality
of percentages of the first coating and a plurality of percentages of the second coating.
[0049] FIG. 4 illustrates one example of a faucet plumbing fixture having a final ombré
appearance whereby a first coating is positioned toward a first end of the faucet, a second coating
is positioned toward a second end of the faucet, and a transition region is positioned
therebetween.
[0050] In one embodiment, the removing step includes a chemical separation process, whereby
after the third step 300 of masking a portion of the plumbing fixture and the fourth step 400 of
depositing the second coating atop both the protected portion coated with the masking material
and the unprotected portion coated by only the first coating, the sacrificial mask material is
washed out together with overlying portions of the second coating to leave exposed portions of
the first coating that was protected by the mask. Selection of chemical solvents are evaluated for
selective removal of the mask material. In other words, solvents must be chosen to selectively
disengage the masking material from the first coating without substantially attacking either the
first coating or the second coating.
[0051] In one exemplary embodiment, where boron nitride was used as the mask material, an
acid wash was conducted comprising water and a mixture of acids such as sulfuric acid (H2SO4)
and hydrofluorosilicic (HFC) acid. Other acids which may be included in the mixture include
mineral acids (e.g., nitric acid (HNO3), hydrochloric acid (HCl), hydrofluoric acid (HF), and
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phosphoric acid (H3PO4)) and organic acids (acetic acid (CH3COOH) and formic acid (CH2O2)).
The acid components of the acid wash facilitate removal of boron nitride by affecting the
residual suspension binder (e.g., bentonite, alumina bentonite, or alumina) phases or by slightly
dissolving the substrate enough to get the boron nitride layer to release. The pH of the acid wash
solution may be in a range of 1 to 5. One example of a contemplated acid wash is an aqueous
solution comprising a mixture of 3.5% concentrated sulfuric acid and a 23% hydrofluorosilicic
acid solution at about 40°C. In another exemplary embodiment, water-based or organic solventbased
boron nitride coatings may be removed by exposure to water or solvent (e.g., ethanol,
acetone, or combinations thereof), respectively.
[0052] In yet another exemplary embodiment, masking materials may also be removed using
frictional mechanical techniques such as light sandpapering, wire-brushing, grit-blasting or shotblasting,
CO2 (dry ice) blasting, or ultrasonic-cleaning baths. Although the present application
discusses examples in which the surface transitions from one coating to another, it is possible
that additional transitions may be provided according to other exemplary embodiments (e.g.,
three or more colors may be used, with a graduated transition between each using similar
masking and deposition processes as described herein).
[0053] In another embodiment, the ombré appearance may also be achieved without the
masking material as described herein. For example, it is contemplated that the gradient of the
second coating is positioned on the first coating without having to remove the plumbing fixture
from the vacuum chamber after deposition of the first coating. As shown in FIG. 6, plumbing
fixture 600 remains in the vacuum chamber after deposition of the first coating and is partially
covered with a shroud 602 such that a first portion 604 is completely exposed to the vacuum
environment for deposition of the second coating. First portion 604 (i.e., below line a) will
experience substantially complete (i.e., about 100%) coverage with the second coating. After
coating of the first portion 604 is complete the shroud 602 is gradually and continuously shifted
upwards till some amount of the second coating reaches a predetermined position b along the
plumbing fixture 600. The section of the plumbing fixture between a and b represents the
transition region 606 (e.g., see also FIG. 1) where there is a gradual transition from the second
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coating to the first coating. Position b’ represents the maximum height along the plumbing
fixture to which the shroud 602 may be shifted and is along the same horizontal plane as the
portion 608 of the fixture comprising substantially complete (i.e., about 100%) coverage with the
first coating. In other words, above position b (and therefore b’), the fixture comprises
substantially no (i.e., about 0%) coverage with the second coating (and about 100% coverage
with the first coating). The shroud may be shifted at a constant or varying linear speed, with the
shift rate dependent on the desired pattern of the ombré appearance. In some exemplary
embodiments, the fixture may be rotated within the vacuum chamber during deposition.
[0054] In yet another embodiment, the ombré appearance may also be achieved without the
masking material as described herein. For example, it is contemplated that the ombré appearance
may be applied using a single, continuous PVD process whereby a first flow of material
comprising a first coating gradually transitions to a second flow of material comprising a second
coating as a shroud is gradually shifted across a dimension of the plumbing fixture. Much like
the embodiment of FIG. 6, the shroud may be shifted at a constant or varying linear speed, with
the shift rate dependent on the desired pattern of the ombré appearance. In some exemplary
embodiments, the fixture may be rotated within the vacuum chamber during deposition.
[0055] FIG. 7 illustrates one exemplary embodiment of the single, continuous PVD process,
whereby a fixture 700 is placed inside a PVD chamber and shrouded 708 to expose only a first
portion 702 of the fixture 700 where substantially complete coverage of the first coating is
desired. The first flow of material comprising the first coating enters the chamber and the
exposed first portion 702 is coated (i.e., about 100%) with the first coating. Upon completion of
coating the first portion 702, the first portion 702 is shrouded and at the same time, the first flow
is gradually decreased while the second flow of material comprising the second coating is
gradually increased. In other words, a second portion 704 which is the transition segment and
positioned adjacent to the first portion 702 is exposed to the dual first and second flow. For
example, the second portion 704 may be divided into a predetermined number of regions, with
each subsequent region being positioned gradually away from the first portion 702 (e.g., first
region 704a adjacent to first portion 702, second region 704b adjacent to first region 704a and
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separated from first portion 702 by first region 704a, third region adjacent to second region and
separated from first portion by first and second regions, etc.). In the coating process of the
second portion 704, only the first region 704a of the second portion 704 is exposed to the dual
flow, which would comprise mostly the first material and a trace amount of second material.
After the first region 704a is coated, the first region 704a is shrouded and the second region 704b
is exposed to the dual flow, this time with a decreased amount of first material and an increased
amount of second material as in the first region 704a. This process continues until the last region
704n of the second portion 704 experiences a dual flow comprising mostly the second material
and a trace amount of first material. After the second portion 704 (i.e., the transition segment) is
complete, both the first portion 702 and the second portion 704 are shrouded and a third portion
706 of the fixture, where substantially complete coverage of the second coating is desired, is
exposed to the second flow of material comprising the second coating to achieve substantially
complete coverage (i.e., about 100%) with the second coating.
[0056] The present disclosure describes a novel method for forming a multicolor finish.
Benefits of the fabrication methods described herein include forming a dual-coated, graded
appearance having a transition region (from the first appearance coating to the second
appearance coating) without any apparent cloudiness or diffused finish distortion or transition
region defects. Moreover, the use of PVD deposition in forming the first and second coatings
results in robust, long-lasting finishes at mostly any desired purity to achieve predetermined
aesthetic standards for the plumbing fixture.
[0057] As utilized herein, the terms “approximately,” “about,” “substantially”, and similar
terms are intended to have a broad meaning in harmony with the common and accepted usage by
those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should
be understood by those of skill in the art who review this disclosure that these terms are intended
to allow a description of certain features described and claimed without restricting the scope of
these features to the precise numerical ranges provided. Accordingly, these terms should be
interpreted as indicating that insubstantial or inconsequential modifications or alterations of the
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subject matter described and claimed are considered to be within the scope of the invention as
recited in the appended claims.
[0058] References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,”
etc.) are merely used to describe the orientation of various elements in the FIGURES. It should
be noted that the orientation of various elements may differ according to other exemplary
embodiments, and that such variations are intended to be encompassed by the present disclosure.
[0059] The construction and arrangement of the elements of the multi-colored finishes for
plumbing fixtures and methods of fabrication thereof as shown in the exemplary embodiments
are illustrative only. Although only a few embodiments of the present disclosure have been
described in detail, those skilled in the art who review this disclosure will readily appreciate that
many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and
proportions of the various elements, values of parameters, mounting arrangements, use of
materials, colors, orientations, etc.) without materially departing from the novel teachings and
advantages of the subject matter recited. For example, elements shown as integrally formed may
be constructed of multiple parts or elements, the position of elements may be reversed or
otherwise varied, and the nature or number of discrete elements or positions may be altered or
varied.
[0060] Additionally, the word “exemplary” is used to mean serving as an example, instance, or
illustration. Any embodiment or design described herein as “exemplary” is not necessarily to be
construed as preferred or advantageous over other embodiments or designs (and such term is not
intended to connote that such embodiments are necessarily extraordinary or superlative
examples). Rather, use of the word “exemplary” is intended to present concepts in a concrete
manner. Accordingly, all such modifications are intended to be included within the scope of the
present disclosure. Other substitutions, modifications, changes, and omissions may be made in
the design, operating conditions, and arrangement of the preferred and other exemplary
embodiments without departing from the scope of the appended claims.
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[0061] Other substitutions, modifications, changes and omissions may also be made in the
design, operating conditions and arrangement of the various exemplary embodiments without
departing from the scope of the present invention. For example, any element disclosed in one
embodiment may be incorporated or utilized with any other embodiment disclosed herein. Also,
for example, the order or sequence of any process or method steps may be varied or resequenced
according to alternative embodiments. Any means-plus-function clause is intended to
cover the structures described herein as performing the recited function and not only structural
equivalents but also equivalent structures. Other substitutions, modifications, changes and
omissions may be made in the design, operating configuration, and arrangement of the preferred
and other exemplary embodiments without departing from the scope of the appended claims.
[0062] While this specification contains many specific exemplary embodiment details, these
should not be construed as limitations on the scope of any inventions or of what may be claimed,
but rather as descriptions of features specific to particular embodiments of particular inventions.
Certain features that are described in this specification in the context of separate embodiments
can also be implemented in combination in a single embodiment. Conversely, various features
that are described in the context of a single embodiment can also be implemented in multiple
embodiments separately or in any suitable sub-combination. Moreover, although features may
be described above as acting in certain combinations and even initially claimed as such, one or
more features from a claimed combination can in some cases be excised from the combination,
and the claimed combination may be directed to a sub-combination or variation of a subcombination.
[0063] Similarly, while operations are depicted in the drawings in a particular order, this
should not be understood as requiring that such operations be performed in the particular order
shown or in sequential order, or that all illustrated operations be performed, to achieve desirable
results. In certain circumstances, multitasking and parallel processing may be advantageous.
Moreover, the separation of various system components in the embodiments described above
should not be understood as requiring such separation in all embodiments, and it should be
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understood that the described program components and systems can generally be integrated
together in a single software product or packaged into multiple software products.
[0064] Thus, particular embodiments of the subject matter have been described. In some cases,
the actions recited herein can be performed in a different order and still achieve desirable results.
In addition, the processes depicted in the accompanying figures do not necessarily require the
particular order shown, or sequential order, to achieve desirable results. In certain exemplary
embodiments, multitasking and parallel processing may be advantageous.

We claim:
1. A method of applying a multi-color finish to a plumbing fixture comprising:
depositing a first coating on the plumbing fixture;
selectively applying a masking material in a graduated fashion over at least a
portion of the first coating to define a gradient from a first portion of the plumbing fixture that is
substantially completely covered by the masking material to a second portion of the plumbing
fixture that has substantially no masking material;
depositing a second coating over the masking material; and
removing the masking material from the plumbing fixture such that the plumbing
fixture has a surface finish including a transition region representing a gradual transition between
the first coating and the second coating.
2. The method according to Claim 1, wherein the transition region includes a first
percentage of the first coating and a second percentage of the second coating.
3. The method according to Claim 2, wherein the first percentage is in a range of
about 5% to about 95% with the remaining balance as the second percentage.
4. The method according to Claim 1, wherein the transition region includes a
plurality of percentages of the first coating and a plurality of percentages of the second coating.
5. The method according to Claim 1, wherein the first coating defines a first finish
having a first appearance, and wherein the second coating defines a second finish having a
second appearance that is different from the first appearance.
6. The method according to Claim 5, wherein the first finish and the second finish
are selected from at least one of polished chrome, brushed chrome, polished French gold,
polished titanium, brushed titanium, polished rose gold, polished modern gold, polished
tungsten, polished modern brass, satin titanium, polished satin chrome, satin bronze, polished
brass, satin brass, oil-rubbed bronze, polished nickel, brushed nickel, or matte black.
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7. The method according to any one of Claims 1-5, wherein the step of depositing
the first coating and the step of depositing the second coating are conducted using at least one of
physical vapor deposition (PVD), chemical vapor deposition (CVD), atomic layer deposition
(ALD), electroplating, dip coating, or spray coating.
8. The method according to Claim 7, wherein the step of depositing the first coating
and the step of depositing the second coating are each conducted using physical vapor deposition
(PVD), and wherein the PVD is conducted as the plumbing fixture is rotated on a turntable.
9. The method according to Claim 8, wherein the PVD is selected from at least one
of cathodic-arc evaporation, sputter deposition, or high-impulse power magnetron sputtering
(HIPIMS).
10. The method according to any one of Claims 1-5, wherein the masking material
includes at least one of molybdenum disulfide, tungsten disulfide, boron nitride, or graphite.
11. The method according to Claim 10, wherein after the step of masking, the
masking material is cured at a temperature in a range of about 60°C to about 250°C for a time in
a range of about 15 minutes to about 120 minutes.
12. The method according to Claim 10, wherein the masking material is applied by a
technique selected from the group consisting of printing, powder coating, painting, spraying,
dipping, brushing, and dry-powder tumbling.
13. The method according to any one of Claims 1-5, wherein the masking material is
applied by spraying, and wherein the spraying is conducted as the plumbing fixture is rotated on
a turntable.
14. The method according to any one of Claims 1-5, wherein the step of depositing
the second coating comprises depositing the second coating on the first portion and the second
portion.
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15. The method according to any one of Claims 1-5, wherein the step of removing the
masking material comprises washing the plumbing fixture using at least one of a water-based
wash, an acid wash, or an organic solvent-based wash.