Process for forming multi-layer coatings on three-dimensional multi-faced substrates and product made according to such process

Abstract

A process for forming and drying a multi-layer composite coating on an elongated three-dimensional multi-faced substrate is provided. The process includes the following steps: (1) passing the substrate to a first coating station located on a coating line; (2) applying a base coating composition to the entire exterior surface of the substrate as it passes through the first coating station, thereby forming a base coat on the substrate; (3) passing the substrate from step (2) to a first drying station located on the coating line; (4) drying the base coat as it passes through the first drying station; (5) passing the substrate from step (4) to a second coating station located on the coating line; (6) applying a top coating composition, different from the base coating composition, to at least one but not all of the faces of the substrate from step (5) as it passes through the second coating station to form a top coat on a portion of the substrate; (7) passing the substrate from step (6) to a second drying station located on the coating line; and (8) drying the top coat as it passes through the drying station. Substrates coated by the process of the present invention are useful as building components, for example window and door frames, where they provide one exterior-durable surface and one surface suitable as an interior surface.