US20030203194A1 - Coating film for coating on a three-dimensionally curved substrate - Google Patents
Coating film for coating on a three-dimensionally curved substrate Download PDFInfo
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- US20030203194A1 US20030203194A1 US10/423,898 US42389803A US2003203194A1 US 20030203194 A1 US20030203194 A1 US 20030203194A1 US 42389803 A US42389803 A US 42389803A US 2003203194 A1 US2003203194 A1 US 2003203194A1
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- coating
- layer
- coating film
- support base
- coating layer
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/12—Bonding of a preformed macromolecular material to the same or other solid material such as metal, glass, leather, e.g. using adhesives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
- B44C1/16—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like
- B44C1/165—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like for decalcomanias; sheet material therefor
- B44C1/17—Dry transfer
- B44C1/1733—Decalcomanias applied under pressure only, e.g. provided with a pressure sensitive adhesive
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
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- 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
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
- B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
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- 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
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
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- 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
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
- B29C37/0028—In-mould coating, e.g. by introducing the coating material into the mould after forming the article
- B29C37/0032—In-mould coating, e.g. by introducing the coating material into the mould after forming the article the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat
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- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
- B29C43/183—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould
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- 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
- B29C45/14811—Multilayered articles
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- 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
- B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
- B29C63/0065—Heat treatment
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- 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
- B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
- B29C63/22—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using layers or sheathings having a shape adapted to the shape of the article
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J7/00—Adhesives in the form of films or foils
- C09J7/30—Adhesives in the form of films or foils characterised by the adhesive composition
- C09J7/35—Heat-activated
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- 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
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
- B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
- B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
- B29C2035/0827—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using UV radiation
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- 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
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
- B29C37/0028—In-mould coating, e.g. by introducing the coating material into the mould after forming the article
- B29C2037/0042—In-mould coating, e.g. by introducing the coating material into the mould after forming the article the coating being applied in solid sheet form, e.g. as meltable sheet
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- 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
- B29C2791/00—Shaping characteristics in general
- B29C2791/001—Shaping in several steps
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- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/14—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles in several steps
- B29C43/146—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles in several steps for making multilayered articles
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- 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
- B29K2105/24—Condition, form or state of moulded material or of the material to be shaped crosslinked or vulcanised
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- 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
- B29K2105/24—Condition, form or state of moulded material or of the material to be shaped crosslinked or vulcanised
- B29K2105/243—Partially cured
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- 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
- B29K2715/00—Condition, form or state of preformed parts, e.g. inserts
- B29K2715/006—Glues or adhesives, e.g. hot melts or thermofusible adhesives
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
- Y10T428/2809—Web or sheet containing structurally defined element or component and having an adhesive outermost layer including irradiated or wave energy treated component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
- Y10T428/2813—Heat or solvent activated or sealable
- Y10T428/2817—Heat sealable
- Y10T428/2826—Synthetic resin or polymer
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
- Y10T428/2848—Three or more layers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
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- Y10T428/31855—Of addition polymer from unsaturated monomers
- Y10T428/31935—Ester, halide or nitrile of addition polymer
Abstract
Description
- This application claims priority of German application 196 28 966.1, filed Jul. 18, 1996, the entire contents of which are expressly incorporated herein by reference.
- The invention relates to a method for applying a coating film to three-dimensionally curved surfaces of a dimensionally stable substrate and the coating films.
- A process for coating three-dimensionally curved surfaces of dimensionally stable substrates with a coating film is known from patent document EP 361 351 A1. The coating film used there is formed by a supporting film, an adhesive layer, and a coating layer. Before applying the coating film, the radiation-curable coating layer is partially cured so that it is dust-dry. The coating film is then heated and drawn over the substrate that, if appropriate, has also been heated. After application of the coating film is complete, the coating layer is fully cured by thermal means. A hardening reaction between the adhesive layer, the coating layer, and the substrate may simultaneously occur.
- In certain circumstances, different materials in a substrate must be coated independently. For example, transitions between sheet-metal components and plastic components on the body of a passenger car or in a motor vehicle interior are separately coated. This is because the high thermal loading conditions used for metals that are unsuitable for plastic. Unfortunately, the use of different coating films on different materials or surfaces may result in a different coating appearance.
- Furthermore, the coating films have a supporting film which—when the supporting film is arranged centrally—remains on the product or—if the supporting film is arranged on the outside—is detached and if appropriate recycled following application of the coating film. In both cases, expenditure on the material is high, as a result of which the mass of the coating film to be used for coating and also the production costs are high.
- An object of the invention is to provide better methods for applying coating films that are more universally applicable. Furthermore, an object of the invention is to provide a cost-effective coating film capable of being used in coating curved substrates.
- The invention provides a method for coating a three-dimensionally curved surface of a dimensionally stable substrate. The method comprises applying a coating film to the substrate and subjecting the coating film to electromagnetic radiation below the visible spectrum. In addition, the invention provides a coating film comprising two layers: a coating layer having a partially cured, radiation-curable polymer; and an adhesive layer. The composition of the coating layer and the adhesive layer can be selected from the numerous polymeric coating and adhesive materials known in the art, such as those discussed in European patent document EP 0 361 351 and in the Concise Encyclopedia of Polymer Science and Engineering, Wiley Interscience, New York, both of which are specifically incorporated herein by reference.
- In one embodiment, the coating film is heated to the glass transition temperature or slightly above the glass transition temperature of the polymer selected. The substrate can also be heated to that temperature. For example, the polymer of the coating layer can be selected as one having a glass transition temperature of below about 40° C., or preferably below about 30° C.
- In other embodiments, the coating layer comprises a multi-layer structure having an outside layer comprising a fully cured clearcoat. The outside layer being the layer of the coating film that, after the coating film is applied to the substrate, is most external to the substrate or is in contact with the environment. The layers of the of the multi-layer structure may comprise numerous materials known in the art as appropriate for coating films. For example, a layer of the multi-layer structure can comprise a colored thermoplastic polymer material in the thermoplastic state. In addition or alternatively, the outside layer can comprises a fully cured thermosetting polymer and/or a binder material.
- Numerous appropriate binder materials are known in the art and can be used in this invention. Preferred binder materials comprises one or more of the group consisting essentially of phosphazene, a phosphazene resin, a phosphazene derivative, a phosphazene intermediate, a urethane, a urethane derivative, a urethane intermediate, an acrylate, an acrylate derivative, and an acrylate intermediate.
- In other embodiments, the method employs a coating film or coating film apparatus comprising a support base. The support base can be detached from the coating film, or vice versa, prior to applying the coating film to the substrate. The support base can be a film or a surface on which the coating layer, the adhesive layer, or a component of the coating film is stored. Also, the adhesive layer can be added to the coating film before the support base detaches from the coating film. Or, the adhesive layer can first be attached to the support base and thereafter the coating layer can be attached to the adhesive layer.
- In other embodiments, the coating film contains a support base. Numerous support bases are known in the art and can be used in the invention. The adhesive layer and a pre-cured coating layer can be attached to a support base so that, for example, the coating layer is partially cured after being detached from the support base. Also, the coating layer can be partially cured while attached to a support base. In addition, the adhesive layer can be attached to the coating layer after the coating layer is detached from the support base.
- In more detailed aspects, the substrate is subjected to at most a slight load by the full curing by means of the electromagnetic radiation within the claimed wave range. It should be noted here that if the coating layer is fully cured by means of electron beams, the wave image of the electron beams, i.e. with regard to their wavelengths, should be considered.
- In particular, a coating film having only a coating layer and an adhesive layer is also beneficial since it is possible to dispense with the supporting film, which has hitherto been present and which is therefore no longer required. Thus, a supporting film arranged on the outside no longer has to be detached separately from the substrate.
- In addition, the invention is explained in more detail with reference to exemplary embodiments illustrated in the figures. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention and when considered in conjunction with the accompanying drawings.
- FIG. 1 shows a detailed enlargement of a coating film which has been applied to a substrate.
- FIG. 2 shows a detail of an apparatus for producing a coating film according to the invention, in the case of which the adhesive layer is first applied to the support base.
- FIG. 3 shows a detail of an apparatus for producing a coating film according to the invention, in the case of which the coating layer is applied first to the support base.
- FIGS. 4a to f show a coating film for thermoforming and a plurality of process steps of an associated process for foam-backing or backing by injection molding this coating film.
- FIG. 1 illustrates a three-dimensionally
curved substrate 5 comprising aplastic part 6 and a sheet-metal part 7, in particular of a body of a passenger car, onto which substrate acoating film 8 has been applied. - The
coating film 8 is formed by acoating layer 1 and an adhesive layer 4. It is preferred to use a reactivatable adhesive for the adhesive layer 4, since as a result it is simple to store temporarily theentire coating film 8, for example as a roll 9 (FIGS. 2 and 3), prior to its application to asubstrate 5. - If appropriate, the
coating film 8 may additionally have a supportingfilm 13, which has a stabilizing effect and in the present case is arranged centrally, that is to say between the adhesive layer 4 and thecoating layer 1. However, depending on the application the supportingfilm 13 may also be arranged on the outside, that is to say towards thevisible side 10. - Prior to the application of the
coating film 8 and prior to its intermediate storage as aroll 9, the radiation-curable coating layer 1 is partially cured so as to be free from tack and dust-dry. The partial curing may in this case be carried out byradiation 2, such as infrared, heat, ultraviolet and/or electron-beam radiation. - In order for the
coating film 8, which has a partially curedcoating layer 1, to be applied to thesubstrate 5, which is produced from different materials, such that it is free of blisters, folds and the orange-peel effect, it is advantageous to preheat thecoating film 8 and/or thesubstrate 5. - It has proved beneficial here to select for the coating layer1 a coating which has a glass transition temperature of below 40° C., in particular below 30° C., so that, in order to apply the
coating film 8 to thesubstrate 5, thecoating layer 1 can be heated to its glass transition temperature or slightly above its glass transition temperature. - It is sensible to select the heating temperature during application such that the
coating film 8 can be applied elastically. Preferably, the heating temperature is at the same time made to be below a critical temperature for thesubstrate 5, at which temperature there may be some form of destruction with regard to the material of the substrates and/or softening of the material of thesubstrate 5, resulting in, for example, deformation. - This selection of materials for the
coating film 8 with regard to the heating temperature ensures that thesubstrate 5 is not permanently thermally impaired or destroyed. This measure makes it possible, in particular, to providesubstrates 5 made of different materials with thesame coating film 8, as a result of which thesubstrate 5 has the same color appearance over the entire surface of thesubstrate 5. - For full curing, the
coating film 8, which is applied elastically and preferably taut to thesubstrate 5, is exposed to an in particularelectromagnetic radiation 2, the wavelength of which is below that of the visible spectrum. This definition is also understood to include electron beams which, owing to the wave-corpuscle duality present in the wave area, are to be considered in terms of their wavelength. - The
coating layer 1 is fully cured or fully crosslinked by means of theradiation 2. This manner of fully curing thecoating layer 1, expediently with the simultaneous radiation curing of the adhesive layer 4, which is in particular activatable, means that the materials of the substrate are at most subjected to slight loading. - Furthermore, this manner of partial and full curing of the
coating layer 1 makes it possible for thecoating film 8 to be applied thermoplastically and, once applied, to be crosslinked by thermosetting. - The following text gives details of the production of a supporting-film-
free coating film 8, which is particularly beneficial for the above mentioned application. A detail of an apparatus for producing acoating film 8 of this kind is illustrated in FIGS. 2 and 3. - One of the differences between the two illustrations in accordance with FIGS. 2 and 3 is that in the case of the apparatus in accordance with FIG. 2 the adhesive layer4 is applied first to the
support base 3, while in the case of the apparatus in accordance with FIG. 3 thecoating layer 1 is laid down first. - The apparatus, which in structural terms are approximately identical, have an endlessly revolving
support base 3 which, as in the present cases, is formed by the polished surface of a revolving roller. As an alternative, thesupport base 3 may also be formed by a revolving conveyor belt with a smooth surface. As explained below, producing the apparatus to apply the appropriate coating can be achieved in various ways. - In accordance with FIG. 1, the adhesive layer4 is applied to the outer surface, which forms the
support base 3, of the roller by being, for example, rolled on or sprayed on (not shown), which adhesive layer is formed in particular from an activatable hot-melt adhesive. Thecoating layer 1 is then applied to the adhesive layer 4. In the present exemplary embodiment, thecoating layer 1 is applied with the aid of the sprayingnozzle 14. Thecoating layer 1 is partially cured or partially crosslinked during and/or after application and by heating. The partial curing of thecoating layer 1 is performed until thecoating layer 1 is free from tack or until it is dust-dry. - The
coating layer 1 can be applied to the adhesive layer 4 while the adhesive layer 4 is still situated on thesupport base 3. If the adhesive layer 4 is sufficiently stable, thecoating layer 1 can also be applied to the adhesive layer 4 when the adhesive layer 4 has already been detached from thesupport base 3. - In both cases, the partial curing of the
coating layer 1 can be carried out once thecoating film 8 has been detached. If thecoating layer 1 has been applied in the region of the support base, it is sensible to carry out the partial curing while thecoating film 8 is still arranged on thesupport base 3. The particular procedure depends on various factors, such as for example the stability of the adhesive layer 4, inter alia. - In FIG. 3, for the purpose of producing the
coating film 8, thecoating layer 1 is first laid onto thesupport base 3. If this procedure is adopted, it is important, inter alia, for thesupport base 3 to have a high quality, i.e. to be polished, for example. As above, the second layer of thecoating film 8, in this case, therefore, the adhesive layer 4, can then be applied to the partially cured or partially crosslinkedcoating layer 1. Depending on the stability of thecoating layer 1, the partial curing can take place while still on thesupport base 3 or else when thecoating layer 1 has already been detached from thesupport base 3. - In order to detach the
coating layer 1 and/or the adhesive layer 4 and/or the adhesive layer 4 provided with acoating layer 1, the apparatus illustrated in FIGS. 2 and 3 have ascraper 11. - Instead of removing the covering (
coating film 8 or adhesive layer 4 or coating layer 1) applied to thesupport base 3 by means of thescraper 11, or else to assist thescraper 11, the apparatus may also have a blowing device (illustrated by the nozzle 12). The blowing device assists the removal of the respective covering by means of thescraper 11, or is provided to detach the covering by itself. - Heated compressed air is advantageously used to detach the covering by means of the blowing device, since it is then simultaneously-possible partially to dry the
coating layer 1 and/or the activatable adhesive layer 4. - By contrast to, or in addition to, the
nozzle 12 illustrated in FIGS. 2 and 3, the blowing device may also be realized by forming thesupport base 3 from a porous material, through which compressed air is blown onto the underside of the covering to be detached. After detachment from thesupport base 3, the coating film can be applied to a substrate or stored on aroll 9. - It is particularly advantageous if phosphazene and/or phosphazene resin and/or derivatives thereof and/or intermediates thereof are used as binder for the
coating layer 1 or, in the case of a multi-layer structure of thecoating layer 1, at least for the outside layer thereof. - In addition to being easy to process during production and application to
substrate 5,coating films 8 of this kind also have an excellent scratch resistance. - Furthermore, these coating
films 8 may be produced with good environmental compatibility, so that measures required to protect the environment are substantially reduced. Furthermore, these coating films can also be produced cost-effectively. - A further advantage of these
coating films 8 which should be noted is that they are thermoplastic after the partial curing, while after full curing—after thecoating film 8 has been applied—they can be crosslinked as thermosets. Once they have been finally applied, therefore, the coating films can be ground and polished. In the event of minor damage, the ability to be ground and polished offers the advantage that the substrates coated with coating films of this kind are easy to repair by minor touching up. - This fact is beneficial preferably when coating
films 8 of this kind are used as high-quality decorative films, since the latter hitherto generally had to be produced in a cost-intensive and ecologically harmful manner from fluorothermoplastics (e.g. PVDF). Furthermore, coating films based on PVC and PVDF cannot be ground and polished, and are therefore also impossible to repair over small areas. - Furthermore, in the event of a lower scratch resistance of the
coating film 8, it may be sensible to select urethane and/or the derivatives thereof and/or the intermediates thereof as binder for thecoating layer 1 or, in the case of a multi-layer structure of thecoating layer 1, at least for the outside layer thereof. - A further possibility is to select acrylates and/or the derivatives thereof and/or the intermediates thereof for the binder.
- FIG. 4a illustrates a
coating film 8 which is suitable for foam-backing or backing by injection molding with plastic. Thecoating film 8, which is preferred for a process of this kind, in accordance with FIG. 4a has the following layer structure: theouter layer 21 on the visible side consists of clearcoat, thenext layer 22 is a layer which provides color and/or effect, the next layer is an adhesive layer 4 and the final layer, that is to say the layer which faces towards the injection-molded backing, is alayer 23 of material which, when the backing material is injection molded, can be joined, in particular monolithically, to the backing material to be injection molded, without the addition of further substances. Thismaterial layer 23 is preferably produced from the same material as the backing material to be injection molded. - The further FIGS. 4b to 4 f illustrate a plurality of process steps of the associated process for producing an object which is decorated with a
coating film 8 and backed by injection molding (see FIG. 4f). - In FIG. 4b, the coating film is heated thermally, preferably to a temperature in the region of the glass transition temperature of the
coating layer 1 of thecoating film 8, and is thermoformed in particular permanently and without creases, over a male die. 16 by means of vacuum. As illustrated in FIG. 4c, thethermoformed coating film 8 is stamped out in a stamping die 17 to match a desired contour. - The stamped and
thermoformed coating film 8 is placed in aninjection mold 19 and backed by injection molding with a plastic 20 (FIG. 4e). The backing is expediently carried out in the region of the glass transition temperature of the coating layer. In order to form the object, which is to be produced with an injection molded backing and in the ready-decorated state, with the correct shape, when the backing is being carried out theelastic coating film 8 can simultaneously be pressed against the limits of theinjection mold 19, which are formed as a negative image of the desired shape of an object 15 (FIGS. 4d-4 f). After curing the injection-moldedplastic backing 20, the ready-decorated object is detached from theinjection mold 19 and thecoating film 8 is cured by thermosetting by means of radiation curing. - In the case of a multi-layer structure of the
coating layer 1, as illustrated in FIG. 4a, it is possible to cure only theouter layer 21, which in this case is formed from clearcoat, in which case alayer 22, which provides color and/or effect, of thecoating layer 1 remains thermoplastic. A layer which provides effect is to be understood in particular as being those layers which have liquid-crystal substances which are three-dimensionally crosslinked in an oriented manner and have a chiral phase, which pigments give the effect of being a different color depending on the viewing angle. Pigments of this kind are known, in particular, from EP 601 483 B1. This is useful, inter alia, because radiation curing of thelayer 22 which provides color and/or effect is costly in terms of equipment. - If it is nevertheless intended to cure the layer which provides color and/or effect likewise as a thermoset, the full curing of the
layer 22 which provides color and/or effect is preferably carried out by means of electron beams. - In a process of this kind, the
coating film 8 illustrated in FIG. 4a is particularly useful. The layer structure of the coating film is as follows: clearcoat, color and/or effect layer, if appropriate adhesive layer and finally, i.e. facing the injection-molded backing, a layer of material which, when the backing material is injection molded, can be joined, in particular monolithically, to the backing material to be injection molded, without the addition of further substances. This material layer is preferably produced from the same material as the backing material to be injection molded. - Although the invention has been described and illustrated in detail, it is to be clearly understood that the same is by way of illustration and example, and is not to be taken by way of limitation. The spirit and scope of the present invention are to be limited only by the terms of the appended claims.
Claims (24)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/423,898 US20030203194A1 (en) | 1996-07-18 | 2003-04-28 | Coating film for coating on a three-dimensionally curved substrate |
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE19628966A DE19628966C1 (en) | 1996-07-18 | 1996-07-18 | Process for applying a lacquer film on three-dimensional curved surfaces of dimensionally stable substrates |
DE19628966.1 | 1996-07-18 | ||
US08/898,042 US6221439B1 (en) | 1996-07-18 | 1997-07-18 | Method for applying a coating film on a three-dimensionally curved substrate |
US09/810,166 US6596390B1 (en) | 1996-07-18 | 2001-03-19 | Coating film for coating on a three-dimensionally curved substrate |
US10/423,898 US20030203194A1 (en) | 1996-07-18 | 2003-04-28 | Coating film for coating on a three-dimensionally curved substrate |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US09/810,166 Continuation US6596390B1 (en) | 1996-07-18 | 2001-03-19 | Coating film for coating on a three-dimensionally curved substrate |
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US20030203194A1 true US20030203194A1 (en) | 2003-10-30 |
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US08/895,232 Expired - Fee Related US5912081A (en) | 1996-07-18 | 1997-07-16 | Method and paint firm for painting an object during a creative shaping |
US08/898,042 Expired - Lifetime US6221439B1 (en) | 1996-07-18 | 1997-07-18 | Method for applying a coating film on a three-dimensionally curved substrate |
US09/810,166 Expired - Fee Related US6596390B1 (en) | 1996-07-18 | 2001-03-19 | Coating film for coating on a three-dimensionally curved substrate |
US10/423,898 Abandoned US20030203194A1 (en) | 1996-07-18 | 2003-04-28 | Coating film for coating on a three-dimensionally curved substrate |
Family Applications Before (3)
Application Number | Title | Priority Date | Filing Date |
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US08/895,232 Expired - Fee Related US5912081A (en) | 1996-07-18 | 1997-07-16 | Method and paint firm for painting an object during a creative shaping |
US08/898,042 Expired - Lifetime US6221439B1 (en) | 1996-07-18 | 1997-07-18 | Method for applying a coating film on a three-dimensionally curved substrate |
US09/810,166 Expired - Fee Related US6596390B1 (en) | 1996-07-18 | 2001-03-19 | Coating film for coating on a three-dimensionally curved substrate |
Country Status (5)
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US (4) | US5912081A (en) |
EP (2) | EP0819520A3 (en) |
JP (1) | JP3177484B2 (en) |
KR (1) | KR100237251B1 (en) |
DE (2) | DE19654918B4 (en) |
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Also Published As
Publication number | Publication date |
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EP0819520A2 (en) | 1998-01-21 |
EP0819516A2 (en) | 1998-01-21 |
US6596390B1 (en) | 2003-07-22 |
EP0819516A3 (en) | 1999-04-28 |
US6221439B1 (en) | 2001-04-24 |
DE19654918B4 (en) | 2004-08-12 |
JPH1080665A (en) | 1998-03-31 |
KR100237251B1 (en) | 2000-01-15 |
DE19628966C1 (en) | 1997-12-18 |
DE19654918A1 (en) | 1998-01-22 |
KR980009332A (en) | 1998-04-30 |
JP3177484B2 (en) | 2001-06-18 |
EP0819520A3 (en) | 2000-05-31 |
US5912081A (en) | 1999-06-15 |
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