BMC材料用光固化涂料要点.docx

BMC材料用光固化涂料要点.docx

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BMC材料用光固化涂料要点

（54of54）

UnitedStatesPatentApplication

20010002409

KindCode

A1

LAKE,RANDALLT.

May31,2001

LAMPREFLECTORSANDUVCURABLECOMPOSITIONSUSEFULASBASECOATSFORSAME

Abstract

DescribedarepreferredUVcurablecoatingcompositionswhicharesuitableforuseasbasecoatsintheproductionoflampreflectors.Alsodescribedarereflectordevicesandmethodsformakingthem.

Inventors:

LAKE,RANDALLT.;（NEWBURGH,IN）

CorrespondenceNameandAddress:

CHARLESRREEVES

WOODARDEMHARDTNAUGHTON

MORIARTY&MCNETTBANKONECENTERTOWER

111MONUMENTCIRCLESUITE3700

INDIANAPOLIS

IN

462045137

SerialNo.:

201553

SeriesCode:

09

Filed:

November30,1998

U.S.CurrentClass:

522/90;522/79;522/80;522/92;522/96;522/97

U.S.ClassatPublication:

522/90;522/92;522/96;522/97;522/79;522/80

Intern'lClass:

C08F002/46;C08K003/00;C08G002/00;C08J003/28

Claims

Whatisclaimedis:

1.Alampreflector,comprising:

areflectorbodyformedfromglass-reinforcedunsaturatedpolyesterandhavinganareaonwhichtoformareflectivecoatingandatleastoneaperturedefinedinsaidareaforreceivingalampbulb;aUV-curedbasecoatadheredtosaidareacomprisinganacrylatedormethacrylatedpolyesterurethane;andametalfilmadheredtosaidbasecoatsoastoformareflectorsurface.

2.Thelampreflectorofclaim1andalsoincludingatopcoatoversaidmetalfilm.

3.Thelampreflectorofclaim2whereinsaidreflectorsurfacedoesnotblister,crackorhazewhensubjectedto350.degree.F.for2hours.

4.Thelampreflectorofclaim2whereinsaidreflectorsurfacedoesnotblister,crackorhazewhensubjectedto400.degree.F.for2hours.

5.Thelampreflectorofclaim2whereinsaidreflectorsurfacedoesnotblister,crackorhazewhensubjectedto450.degree.F.for24hours.

6.Thelampreflectorofclaim1,whereintheUV-curedbasecoatcomprisesabout10%toabout20%ofanacrylatedormethacrylatedpolyesterurethanehavinganumberaveragemolecularweightofabout500toabout2000,about40%toabout60%oftrifunctionalacrylate,about5%toabout15%ofanepoxydiacrylate,andabout3%toabout15%ofaphotoinitiator.

7.Thelampreflectorofclaim1,whereintheUV-curedbasecoatcomprisesabout25%toabout45%ofanacrylatedormethacrylatedpolyesterurethanehavinganumberaveragemolecularweightofabout500toabout2000,about45%toabout65%ofatriacrylate,andabout3%toabout10%ofaphotoinitiator.

8.Thelampreflectorofclaim1,whereinsaidUV-curedbasecoatcomprisesabout15%toabout30%ofanacrylatedormethacrylatedpolyesterurethanehavinganumberaveragemolecularweightofabout500toabout2000,about1%toabout10%ofanacrylatedormethacrylatedpolyetherurethanehavinganumberaveragemolecularweightofabout1200toabout2600,about40%toabout60%oftrifunctionalacrylate,about5%toabout15%ofanepoxydiacrylate,andabout3%toabout15%ofaphotoinitiator.

9.Thelampreflectorofclaim1,whereinsaidUV-curedbasecoatcomprisesabout70%toabout90%ofanacrylatedormethacrylatedpolyesterurethanehavinganumberaveragemolecularweightofabout500toabout2000,about3%toabout15%ofaphotoinitiator,andabout3%toabout15%ofasecondacrylatedormethacrylatedurethanehavingamolecularweightgreaterthanthatofsaidacrylatedormethacrylatedpolyesterurethane.

10.Thelampreflectorofclaim1,whereinsaidreflectorsurfacecomprisesapluralityofflutesorfacets.

11.Thelampreflectorofclaim10,whereinsaidreflectorsurfacecomprisesapluralityofflutes.

12.Anultravioletcurablecoatingcomposition,comprisingasolvent,and,exclusiveofthesolvent,about10%toabout20%ofanacrylatedormethacrylatedpolyesterurethanehavinganumberaveragemolecularweightofabout500toabout2000,about40%toabout60%oftrifunctionalacrylate,about5%toabout15%ofanepoxydiacrylate,andabout3%toabout15%ofaphotoinitiator.

13.Thecompositionofclaim12whereinsaidsolventconstitutesabout75%toabout45%ofthecompositionand,takentogether,theacrylatedormethacrylatedpolyesterurethane,trifunctionalacrylate,epoxydiacrylateandphotoinitiatorconstituteabout25%toabout55%ofthecomposition.

14.Anultravioletcurablecoatingcompositionsuitableforformingabasecoatonametallizedplasticmoldedarticle,comprisingasolventand,exclusiveofthesolvent,about25%toabout45%ofanacrylatedormethacrylatedpolyesterurethanehavinganumberaveragemolecularweightofabout500toabout2000,about45%toabout65%ofatrifunctionalacrylate,andabout3%toabout15%ofaphotoinitiator.

15.Thecompositionofclaim14whereinsaidsolventconstitutesabout75%toabout45%ofthecompositionand,takentogether,theacrylatedormethacrylatedpolyesterurethane,trifunctionalacrylate,andphotoinitiatorconstituteabout25%toabout55%ofthecomposition.

16.Anultravioletcurablecoatingcompositionsuitableforformingabasecoatonametallizedplasticmoldedarticle,comprisingasolventand,exclusiveofthesolvent,about15%toabout30%ofanacrylatedormethacrylatedpolyesterurethanehavinganumberaveragemolecularweightofabout500toabout2000,about1%toabout15%ofanacrylatedormethacrylatedpolyetherurethanehavinganumberaveragemolecularweightofabout1200toabout2600,about40%toabout60%oftrifunctionalacrylate,about5%toabout15%ofanepoxydiacrylate,andabout3%toabout15%ofaphotoinitiator.

17.Thecompositionofclaim16whereinsaidsolventconstitutesabout75%toabout45%ofthecompositionand,takentogether,theacrylatedormethacrylatedpolyesterurethane,acrylatedormethacrylatedpolyetherurethane,trifunctionalacrylate,epoxydiacrylate,andphotoinitiatorconstituteabout25%toabout55%ofthecomposition.

18.Anultravioletcurablecoatingcompositionsuitableforformingabasecoatonametallizedplasticmoldedarticle,comprisingasolvent,and,exclusiveofthesolvent,about70%toabout90%ofanacrylatedormethacrylatedpolyesterurethanehavinganumberaveragemolecularweightofabout500toabout2000,about3%toabout15%ofaphotoinitiator,andabout3%toabout15%ofasecondacrylatedormethacrylatedurethanehavingamolecularweightgreaterthanthatoftheacrylatedormethacrylatedpolyesterurethane.

19.Thecompositionofclaim18whereinsaidsolventconstitutesabout75%toabout45%ofthecompositionand,takentogether,theacrylatedormethacrylatedpolyesterurethane,secondacrylatedormethacrylatedurethaneandphotoinitiatorconstituteabout25%toabout55%ofthecomposition.

20.Ametallizedmoldedplasticarticle,comprising:

amoldedplasticsubstrate;aUV-curedbasecoatcomprisinganacrylatedormethacrylatedpolyesterurethaneadheredtosaidsubstrate;ametalfilmadheredtosaidbasecoatsoastoformareflectorsurface;andatopcoatoversaidmetalfilm;whereinsaidreflectorsurfacedoesnotblister,crackorhazewhensubjectedto350.degree.F.for2hours.

Description

BACKGROUNDOFTHEINVENTION

[0001]Thepresentinventionrelatesgenerallytoultraviolet（UV）curablecoatingcompositionsandtheiruseasbasecoatsonmetallizedmoldedplasticarticlessuchaslampreflectors.

[0002]Asfurtherbackground,metallizedplasticmoldedarticlesaremulti-layerstructureswhichincludeamoldedsubstrate,abasecoatonthesubstrate,andametalfilmadheredtothebasecoat.Further,metallizedplasticmoldedarticlesmayincludeoneormoreadditionalcoatingsontopofthemetalfilm,forexample,theymaysimplyincludeatopcoatormayincludeaninterlayerandatopcoat.

[0003]Thebasecoatisahighlyimportantcomponentofmetallizedmoldedplasticarticles.Thebasecoatmustadherewelltotheplasticsubstrateandtothemetalfilm.Additionally,thebasecoatmustbeofauniformthicknessacrossthecoatedareaofthesubstrateinordertoprovideasmooth,lusterousappearancetothemetallizedarticleand,inthecaseofmetallizedarticleshavingexactingopticalstandards,e.g.reflectors,topreservetheintendedopticsofthefinaldevice.Aproblemwhichhasbeenencounteredinthepriorartisthatbasecoatshavenotpossessedgoodedge-coatingorlevelingproperties.Rather,basecoatsusedinthepasthavetendedtodraworcreepawayfromedgesofthesubstratethusleavingonlyathincoatingornocoatingnearthesubstrateedges,orhavetendedtogatheratedgesandcuretoformanundesiredridgeorraisedportion.Inthecaseofautomobilelampreflectors,thisproblemhashamperedtheproductionofquality,substantiallysmooth-surfacedreflectorswhichareusedinconjunctionwithlenseswhichcontainopticalstructuretoachieveappropriatedistributionoflight.

[0004]Moreover,atrendexistsintheautomobileindustrytoeliminateopticalstructuresfromheadlamplensesandratherbuildthemintotheassociatedreflectors.Suchreflectorshavingbuilt-inopticalstructuresinclude,forexample,flutedand/orfacetedreflectors（seeforinstanceU.S.Pat.Nos.4,704,661and5,034,867）.Flutedreflectorsincludeapluralityofconvexfluteswhichintroducealternatinggroovesandridgesorhumpswithinthereflectorsurface.Facetedreflectorshaveapluralityofdiscreetreflectivesurfaceswhichintroducegroovesand/oredgesbetweenthediscreetsurfaces.Basecoatshavingpooredge-coatingandlevelingpropertiespresentspecialproblemswithsuchopticalreflectorsbecausethinningorgatheringonorbetweentheirstructuralfeaturesinterfereswiththeintendedoptics.

[0005]Basecoatsonmetallizedplasticmo