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