GB2319744A - Moulding a component having a scratch resistant coating and a plastics base - Google Patents
Moulding a component having a scratch resistant coating and a plastics base Download PDFInfo
- Publication number
- GB2319744A GB2319744A GB9801857A GB9801857A GB2319744A GB 2319744 A GB2319744 A GB 2319744A GB 9801857 A GB9801857 A GB 9801857A GB 9801857 A GB9801857 A GB 9801857A GB 2319744 A GB2319744 A GB 2319744A
- Authority
- GB
- United Kingdom
- Prior art keywords
- resin
- substrate
- glass
- coating
- mould
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0013—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor using fillers dispersed in the moulding material, e.g. metal particles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14467—Joining articles or parts of a single article
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1642—Making multilayered or multicoloured articles having a "sandwich" structure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/10—Thermosetting resins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/16—Fillers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2011/00—Optical elements, e.g. lenses, prisms
- B29L2011/0016—Lenses
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3052—Windscreens
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Non-Portable Lighting Devices Or Systems Thereof (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
A method of forming a translucent scratch resistant coating on a plastics substrate comprises mixing a clear resin together with a glass filler material (eg. glass beads) and dual injecting the mixture and the substrate into a mould so that the mixture forms a coating on the substrate Preferably the resin is a thermosetting polyester provided in the form of a powdered paint containing u-v protection additives and the substrate is a polycarbonate material. The method is particularly suitable for producing components such as vehicle headlamp lenses and windows.
Description
A METHOD OF PRODUCING A SCRATCH RESISTANT COATING
ON A PLASTICS SUBSTRATE
The invention relates to a method of producing a scratch resistant coating on a plastics substrate and is particularly, but not exclusively, concerned with the production of a translucent component such as a lamp lens or window for use on a motor vehicle.
For some time. polycarbonate plastics material as a clear moulding has been applied as a replacement for windows and lenses as it has specific weight advantages. Polycarbonate lenses and glass have substantially equal transparency but polycarbonate is less resistant to scratching than glass. In order to improve scratch resistance special siloxane coatings have been produced for coating the moulded poivcarbonate for protection. Such siloxane coating involves dip, brush or spray application techniques in a clean environment and subsequent curing.
An object of the present invention is to provide an improved scratch-resistant
coating suitable for use with polycarbonates or other substrates of plastic material
where a scratch resistant coating is required.
According to one aspect of the invention there is provided a method of producing a translucent scratch resistant coating on a plastic substrate comprising providing a non-pigmented resin material, mixing the resin with a glass filler material and causing the resin and glass mixture to form the coating on a substrate in a mould, wherein the coating and the substrate are formed by dual injection in which the resin is mixed with glass filler particles and the mixture is dual injected with the substrate material into the mould to form the coated component.
By using a method in accordance with the invention, the coating can be produced by an in-mould coating technique which does not involve dip, brush or spray coating of a substrate. The in-mould method also enables such components to be produced accurately with a surface finish dictated by the mould surface without the need for special clean environments.
Moreover, the use of the glass filler material provides an extremely hard coating for the substrate which is highly resistant to scratching.
The resin and glass mixture may form the coating over substantially the whole of the injected substrate material.
The resin is preferably a clear thermoset resin, such as a polyester resin powder having ultra violet protection additives. One suitable material is
Interpon (R.T.M.) JZ004D available from Courtaulds.
A preferred use of the method is in the production of translucent components such as vehicle headlamp lenses and windows. In such a case the substrate preferably comprises polycarbonate material to provide the required degree of translucence and toughness. The resin preferably has a refractive index substantially the same as that of the glass filler material.
The materials produced by the methods referred to above are novel.
Hence, according to a second aspect of the invention there is provided a scratch resistant translucent material produced by a method according to said first aspect and , according to a third aspect of the invention there is provided an article such as vehicle component made by a method in accordance with said first aspect.
Similarly, it is novel to use the methods described above in the production of translucent components such as vehicle headlamp lenses and windows. Hence, according to a fourth aspect, the invention also provides use of the method according to said first aspect in the production of translucent components such as vehicle headlamp lenses and windows.
The present application is divided from application no. 9703688.3 (published as GB-A- 2 305 890) which describes and claims a method of producing a translucent scratch resistant coating on a plastic substrate comprising providing a non-pigmented resin material, mixing the resin with a glass filler material and causing the resin and glass mixture to form the coating on a substrate in a mould, wherein the coating and the substrate are formed by dual injection in which the glass is provided in the form of a fibrous glass mat by placing the mat in the mould and the resin and the substrate material are dual injected into the mould whereby the resin is injected ahead of the substrate material in order to impregnate the glass mat so that the resin impregnated glass mat forms the coating on the substrate.
In essence the present invention differs from that described and claimed in application no. 9703688.3 in that the fibrous glass mat is replaced by glass fibres or particles. Hence a method in accordance with the present invention and components made by such a method will now be described by way of example as a modification to the method and components described in application no. 9703688.3 and with reference to the accompanying drawings, in which: Fig. 1 is a diagrammatic cross-section through a two-section mould with a glass mat shown in position therein ready for dual injection in accordance with the method claimed in application no. 9703688.3; and
Fig.2 is a view of the mould of Fig.1 in a closed position following dual injection.
In Figs.1 and 2, a mould 10 comprises first and second sections 12, 13 the first section 12 defining a cavity 11 having a female mould surface 14 complementary to a male mould surface 15 on the second mould section 13.
The mould section 13 is formed with an injection passage 16 through which plastics material can be injected from an injection moulding machine (not shown).
The component is formed by means of dual injection. In that respect the mould 10 is mounted on a dual-injection moulding machine of known kind which is arranged to inject a resin R slightly ahead of a polycarbonate substrate material P. Initially, a glass fibre mat 22 is placed in the mould 10 as shown in Fig.1. Injection of the polycarbonate P causes the polycarbonate to spread the resin R over and impregnate the glass mat 22.
Injection is continued until the entire mould cavity 11 is coated with the resin R as in Fig.2 and the resin envelopes the injected polycarbonate P.
After curing, the formed component is removed from the mould. It will be appreciated that the dual injection method provides an all-round coating which may be advantageous in certain applications. However, the scratch resistant coating formed by the resin impregnated glass mat 22 is applied only to a given area of the moulding.
A suitable resin R is Interpon (RTM) J2004D mentioned above which is a non-pigmented polyester resin having ultraviolet protection properties.
In accordance with the present invention, instead of positioning a glass fibre mat 22 in the mould 10 as shown in Fig.1, the resin R is mixed with glass fibres or other glass particles prior to injection. For example, if glass flakes are used it is possible to achieve substantial alignment of the flakes with the surface of the coating during the injection stage such as shown in figures 1 and 2. The entire substrate will then be enveloped in a scratchresistant coating.
It has been found that the glass/resin mixture adheres well to a polycarbonate substrate and provides excellent resistance to scratching making it possible to produce components such as vehicle lamp lenses and windows having a polycarbonate substrate with a scratch resistant surface.
Ideally, the resin and the glass filler will have the same refractive index whereby the finished component with the polycarbonate substrate will have a high degree of transparency.
In-mould coating of components such as vehicle headlamps and windows will enable such components to be made easily in the desired shape with a highly polished external finish without having to provide any especially clean environment. Moreover, if tinting of the components is required, the resin used to impregnate the glass mat or indeed, the substrate itself, can be combined with suitable tinting pigments.
The glass filler can comprise glass beads. The glass beads should have a refractive index substantially similar to that of the resin in which they are to be incorporated. In forming the scratch resistant coating, the resin and glass beads are preferably thoroughly mixed and a volume fraction of greater than 27% glass beads is preferably used. The volume fraction of beads to resin is more preferably in the order of 50% since this is bound to provide strongest hardness and scratch resistance.
The glass beads are preferably in the form of solid or hollow spheres having a diameter less than 100 microns. More preferably, the diameter of the spheres is less than 36 microns and more preferably still between 2.8 and 4.5 microns. Preferably the powdered resin and glass beads are hot pressed at about 180 C for 10 minutes at a low pressure between copper plates coated with release agent.
Claims (13)
1. A method of producing a translucent scratch resistant coating on a
plastic substrate comprising providing a non-pigmented resin material,
mixing the resin with a glass filler material and causing the resin and
glass mixture to form the coating on a substrate in a mould, wherein
the coating and the substrate are formed by dual injection in which the
resin is mixed with glass filler particles and the mixture is dual injected
with the substrate material into the mould to form the coated
component.
2. A method according to Claim 1 wherein the resin and glass mixture
form the coating over substantially the whole of the injected substrate
material.
3. A method according to any preceding claim wherein the resin
material is a thermosetting powdered plastics paint material.
4. A method according to Claim 3 wherein the resin is a polyester resin
powder having ultra violet protection additives.
5. A method according to any preceding claim wherein the substrate
comprises polycarbonate material.
6. A method according to any preceding claim wherein the resin has a
refractive index substantially the same as that of the glass filler
material.
7. A method according to any preceding claim wherein the glass filler
material comprises glass beads.
8. A method according to Claim 8 wherein the glass beads are solid or
hollow spheres.
9. A method according to Claim 7 or 8, wherein the volume fraction of
glass beads to resin material is greater than 27% and more preferably
in the order of 50%.
10. A method according to Claim 7, 8 or 9 wherein the diameter of the
glass beads is less than 100 microns, more preferably less than 36
microns and more preferably still between 2.8 and 4.5 microns.
11. A scratch resistant translucent material produced by a method
according to any preceding claim.
12. An article such as vehicle component made by a method in
accordance with the method of any of Claims 1 to 10.
13. Use of the method according to any one of Claims 1 to 10 in the
production of translucent components such as vehicle headlamp lenses
and windows.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB9801857A GB2319744B (en) | 1994-09-02 | 1995-09-04 | A method of producing a scratch resistant coating on a plastics substrate |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB9417678A GB9417678D0 (en) | 1994-09-02 | 1994-09-02 | A method of producing a scratch resistant coating on a plastics substrate |
GB9801857A GB2319744B (en) | 1994-09-02 | 1995-09-04 | A method of producing a scratch resistant coating on a plastics substrate |
GB9703688A GB2305890B (en) | 1994-09-02 | 1995-09-04 | A method of producing a scratch resistant coating on a plastics substrate |
Publications (3)
Publication Number | Publication Date |
---|---|
GB9801857D0 GB9801857D0 (en) | 1998-03-25 |
GB2319744A true GB2319744A (en) | 1998-06-03 |
GB2319744B GB2319744B (en) | 1998-10-14 |
Family
ID=26305551
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB9703688A Expired - Fee Related GB2305890B (en) | 1994-09-02 | 1995-09-04 | A method of producing a scratch resistant coating on a plastics substrate |
GB9801857A Expired - Fee Related GB2319744B (en) | 1994-09-02 | 1995-09-04 | A method of producing a scratch resistant coating on a plastics substrate |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB9703688A Expired - Fee Related GB2305890B (en) | 1994-09-02 | 1995-09-04 | A method of producing a scratch resistant coating on a plastics substrate |
Country Status (1)
Country | Link |
---|---|
GB (2) | GB2305890B (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2000000338A1 (en) * | 1998-06-26 | 2000-01-06 | Bayerische Motoren Werke Aktiengesellschaft | Improved polymer glazing system |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB9813745D0 (en) * | 1998-06-26 | 1998-08-26 | Rover Group | Improved polymer glazing system |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0605914A1 (en) * | 1992-12-10 | 1994-07-13 | Lankhorst Recycling B.V. | Elongate article having a core and a skin, manufactured from thermoplastic synthetic material, and a method and apparatus for manufacturing such articles |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
SE303592B (en) * | 1963-07-11 | 1968-09-02 | Dynamit Nobel Ag | |
DE2548751A1 (en) * | 1975-10-31 | 1977-05-05 | Demag Kunststofftech | Fibre-reinforced plastics moulded with oriented fixed fibres - using mechanical fibre location giving prods. with required fibre orientation |
JP2503782B2 (en) * | 1990-12-21 | 1996-06-05 | 住友化学工業株式会社 | Molding method for multi-layer molded products |
-
1995
- 1995-09-04 GB GB9703688A patent/GB2305890B/en not_active Expired - Fee Related
- 1995-09-04 GB GB9801857A patent/GB2319744B/en not_active Expired - Fee Related
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0605914A1 (en) * | 1992-12-10 | 1994-07-13 | Lankhorst Recycling B.V. | Elongate article having a core and a skin, manufactured from thermoplastic synthetic material, and a method and apparatus for manufacturing such articles |
Non-Patent Citations (1)
Title |
---|
WPI ABstract Accession Number 93-410952 and JP05310956 * |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2000000338A1 (en) * | 1998-06-26 | 2000-01-06 | Bayerische Motoren Werke Aktiengesellschaft | Improved polymer glazing system |
Also Published As
Publication number | Publication date |
---|---|
GB9801857D0 (en) | 1998-03-25 |
GB2319744B (en) | 1998-10-14 |
GB2305890A (en) | 1997-04-23 |
GB2305890B (en) | 1998-10-14 |
GB9703688D0 (en) | 1997-04-09 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
732E | Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977) | ||
732E | Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977) | ||
PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 20090904 |