BMC材料用光固化涂料要点.docx

1、BMC材料用光固化涂料要点 ( 54 of 54 )United States Patent Application20010002409 Kind Code A1 LAKE, RANDALL T. May 31, 2001 LAMP REFLECTORS AND UV CURABLE COMPOSITIONS USEFUL AS BASECOATS FOR SAME AbstractDescribed are preferred UV curable coating compositions which are suitable for use as basecoats in the pro

2、duction of lamp reflectors. Also described are reflector devices and methods for making them. Inventors:LAKE, RANDALL T.; (NEWBURGH, IN) Correspondence Name and Address: CHARLES R REEVES WOODARD EMHARDT NAUGHTON MORIARTY & MCNETT BANK ONE CENTER TOWER 111 MONUMENT CIRCLE SUITE 3700 INDIANAPOLIS IN 4

3、62045137Serial No.: 201553Series Code: 09 Filed: November 30, 1998U.S. Current Class:522/90; 522/79; 522/80; 522/92; 522/96; 522/97 U.S. Class at Publication:522/90; 522/92; 522/96; 522/97; 522/79; 522/80 Internl Class: C08F 002/46; C08K 003/00; C08G 002/00; C08J 003/28ClaimsWhat is claimed is: 1. A

4、 lamp reflector, comprising: a reflector body formed from glass-reinforced unsaturated polyester and having an area on which to form a reflective coating and at least one aperture defined in said area for receiving a lamp bulb; a UV-cured basecoat adhered to said area comprising an acrylated or meth

5、acrylated polyester urethane; and a metal film adhered to said basecoat so as to form a reflector surface. 2. The lamp reflector of claim 1 and also including a topcoat over said metal film. 3. The lamp reflector of claim 2 wherein said reflector surface does not blister, crack or haze when subjecte

6、d to 350.degree. F. for 2 hours. 4. The lamp reflector of claim 2 wherein said reflector surface does not blister, crack or haze when subjected to 400.degree. F. for 2 hours. 5. The lamp reflector of claim 2 wherein said reflector surface does not blister, crack or haze when subjected to 450.degree.

7、 F. for 24 hours. 6. The lamp reflector of claim 1, wherein the UV-cured basecoat comprises about 10% to about 20% of an acrylated or methacrylated polyester urethane having a number average molecular weight of about 500 to about 2000, about 40% to about 60% of trifunctional acrylate, about 5% to ab

8、out 15% of an epoxy diacrylate, and about 3% to about 15% of a photoinitiator. 7. The lamp reflector of claim 1, wherein the UV-cured basecoat comprises about 25% to about 45% of an acrylated or methacrylated polyester urethane having a number average molecular weight of about 500 to about 2000, abo

9、ut 45% to about 65% of a triacrylate, and about 3% to about 10% of a photoinitiator. 8. The lamp reflector of claim 1, wherein said UV-cured basecoat comprises about 15% to about 30% of an acrylated or methacrylated polyester urethane having a number average molecular weight of about 500 to about 20

10、00, about 1% to about 10% of an acrylated or methacrylated polyether urethane having a number average molecular weight of about 1200 to about 2600, about 40% to about 60% of trifunctional acrylate, about 5% to about 15% of an epoxy diacrylate, and about 3% to about 15% of a photoinitiator. 9. The la

11、mp reflector of claim 1, wherein said UV-cured basecoat comprises about 70% to about 90% of an acrylated or methacrylated polyester urethane having a number average molecular weight of about 500 to about 2000, about 3% to about 15% of a photoinitiator, and about 3% to about 15% of a second acrylated

12、 or methacrylated urethane having a molecular weight greater than that of said acrylated or methacrylated polyester urethane. 10. The lamp reflector of claim 1, wherein said reflector surface comprises a plurality of flutes or facets. 11. The lamp reflector of claim 10, wherein said reflector surfac

13、e comprises a plurality of flutes. 12. An ultraviolet curable coating composition, comprising a solvent, and, exclusive of the solvent, about 10% to about 20% of an acrylated or methacrylated polyester urethane having a number average molecular weight of about 500 to about 2000, about 40% to about 6

14、0% of trifunctional acrylate, about 5% to about 15% of an epoxy diacrylate, and about 3% to about 15% of a photoinitiator. 13. The composition of claim 12 wherein said solvent constitutes about 75% to about 45% of the composition and, taken together, the acrylated or methacrylated polyester urethane

15、, trifunctional acrylate, epoxy diacrylate and photoinitiator constitute about 25% to about 55% of the composition. 14. An ultraviolet curable coating composition suitable for forming a basecoat on a metallized plastic molded article, comprising a solvent and, exclusive of the solvent, about 25% to

16、about 45% of an acrylated or methacrylated polyester urethane having a number average molecular weight of about 500 to about 2000, about 45% to about 65% of a trifunctional acrylate, and about 3% to about 15% of a photoinitiator. 15. The composition of claim 14 wherein said solvent constitutes about

17、 75% to about 45% of the composition and, taken together, the acrylated or methacrylated polyester urethane, trifunctional acrylate, and photoinitiator constitute about 25% to about 55% of the composition. 16. An ultraviolet curable coating composition suitable for forming a basecoat on a metallized

18、 plastic molded article, comprising a solvent and, exclusive of the solvent, about 15% to about 30% of an acrylated or methacrylated polyester urethane having a number average molecular weight of about 500 to about 2000, about 1% to about 15% of an acrylated or methacrylated polyether urethane havin

19、g a number average molecular weight of about 1200 to about 2600, about 40% to about 60% of trifunctional acrylate, about 5% to about 15% of an epoxy diacrylate, and about 3% to about 15% of a photoinitiator. 17. The composition of claim 16 wherein said solvent constitutes about 75% to about 45% of t

20、he composition and, taken together, the acrylated or methacrylated polyester urethane, acrylated or methacrylated polyether urethane, trifunctional acrylate, epoxy diacrylate, and photoinitiator constitute about 25% to about 55% of the composition. 18. An ultraviolet curable coating composition suit

21、able for forming a basecoat on a metallized plastic molded article, comprising a solvent, and, exclusive of the solvent, about 70% to about 90% of an acrylated or methacrylated polyester urethane having a number average molecular weight of about 500 to about 2000, about 3% to about 15% of a photoini

22、tiator, and about 3% to about 15% of a second acrylated or methacrylated urethane having a molecular weight greater than that of the acrylated or methacrylated polyester urethane. 19. The composition of claim 18 wherein said solvent constitutes about 75% to about 45% of the composition and, taken to

23、gether, the acrylated or methacrylated polyester urethane, second acrylated or methacrylated urethane and photoinitiator constitute about 25% to about 55% of the composition. 20. A metallized molded plastic article, comprising: a molded plastic substrate; a UV-cured basecoat comprising an acrylated

24、or methacrylated polyester urethane adhered to said substrate; a metal film adhered to said basecoat so as to form a reflector surface; and a topcoat over said metal film; wherein said reflector surface does not blister, crack or haze when subjected to 350.degree. F. for 2 hours. DescriptionBACKGROU

25、ND OF THE INVENTION 0001 The present invention relates generally to ultraviolet (UV) curable coating compositions and their use as basecoats on metallized molded plastic articles such as lamp reflectors. 0002 As further background, metallized plastic molded articles are multi-layer structures which

26、include a molded substrate, a basecoat on the substrate, and a metal film adhered to the basecoat. Further, metallized plastic molded articles may include one or more additional coatings on top of the metal film, for example, they may simply include a topcoat or may include an interlayer and a topco

27、at. 0003 The basecoat is a highly important component of metallized molded plastic articles. The basecoat must adhere well to the plastic substrate and to the metal film. Additionally, the basecoat must be of a uniform thickness across the coated area of the substrate in order to provide a smooth, l

28、usterous appearance to the metallized article and, in the case of metallized articles having exacting optical standards, e.g. reflectors, to preserve the intended optics of the final device. A problem which has been encountered in the prior art is that basecoats have not possessed good edge-coating

29、or leveling properties. Rather, basecoats used in the past have tended to draw or creep away from edges of the substrate thus leaving only a thin coating or no coating near the substrate edges, or have tended to gather at edges and cure to form an undesired ridge or raised portion. In the case of au

30、tomobile lamp reflectors, this problem has hampered the production of quality, substantially smooth-surfaced reflectors which are used in conjunction with lenses which contain optical structure to achieve appropriate distribution of light. 0004 Moreover, a trend exists in the automobile industry to

31、eliminate optical structures from headlamp lenses and rather build them into the associated reflectors. Such reflectors having built-in optical structures include, for example, fluted and/or faceted reflectors (see for instance U.S. Pat. Nos. 4,704,661 and 5,034,867). Fluted reflectors include a plu

32、rality of convex flutes which introduce alternating grooves and ridges or humps within the reflector surface. Faceted reflectors have a plurality of discreet reflective surfaces which introduce grooves and/or edges between the discreet surfaces. Basecoats having poor edge-coating and leveling properties present special problems with such optical reflectors because thinning or gathering on or between their structural features interferes with the intended optics. 0005 Basecoats on metallized plastic mo