WO2000027545A1 - Method of coating a substrate with a polymer having a dichroic material suspended therein - Google Patents

Method of coating a substrate with a polymer having a dichroic material suspended therein Download PDF

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Publication number
WO2000027545A1
WO2000027545A1 PCT/US1998/023257 US9823257W WO0027545A1 WO 2000027545 A1 WO2000027545 A1 WO 2000027545A1 US 9823257 W US9823257 W US 9823257W WO 0027545 A1 WO0027545 A1 WO 0027545A1
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WO
WIPO (PCT)
Prior art keywords
polymer
substrate
layer
curable
dichroic
Prior art date
Application number
PCT/US1998/023257
Other languages
French (fr)
Inventor
John S. Blazy
Andrew A. Sokol
Original Assignee
Uv Coatings, Ltd.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Uv Coatings, Ltd. filed Critical Uv Coatings, Ltd.
Priority to AU14504/99A priority Critical patent/AU1450499A/en
Publication of WO2000027545A1 publication Critical patent/WO2000027545A1/en

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Classifications

    • 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
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/06—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
    • B05D5/065—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects having colour interferences or colour shifts or opalescent looking, flip-flop, two tones
    • B05D5/066—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects having colour interferences or colour shifts or opalescent looking, flip-flop, two tones achieved by multilayers
    • 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
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/52—Two layers
    • B05D7/53—Base coat plus clear coat type
    • B05D7/532—Base coat plus clear coat type the two layers being cured or baked together, i.e. wet on wet

Definitions

  • the present invention relates to a method of coating a substrate. More particularly, the present invention relates to a method of coating a substrate with a polymer. Even more particularly, the present invention relates to a method of coating a substrate with a polymer having a dichroic material suspended therein to create a durable, aesthetically-pleasing polymerized surface.
  • UV-curable coating compositions exhibit many advantages over other coating compositions in their ability to cure in natural sunlight and to provide a hardened surface. Furthermore, by the addition of the appropriate adjuvants, the properties of the film can be tailored to meet the desires of the user.
  • a method of coating a substrate which comprises:
  • the preferred polymer is a UV-curable polymer, although other polymeric compositions, such as an epoxy, a catalyzed resin or the like may be used.
  • the dichroic material is preferably a plastic film, although other media may be used, such as a plastic sheet, particles or glass.
  • the present invention provides a method of coating a substrate with a polymer having a dichroic material suspended therein to create a durable, aesthetically-pleasing polymerized surface.
  • the method of coating a substrate according to the present invention comprises the steps of:
  • Subsequent layers of the polymer may thereafter be applied to the resulting surface of the substrate and cured, if desired, and, in as many layers as desired.
  • the method of the present invention provides for the use of any dichroic material which is capable of being suspended in a polymer according to the method of the present invention.
  • a dichroic material is any material which has color-changing properties. Such dichroic materials are well known to those of ordinary skill in the art and commercially available. Any dichroic material may be used herein so long as it is inert in the polymer.
  • the dichroic material used in the present invention may be a plastic film, a plastic sheet, particles or glass and is, preferably, a plastic film.
  • the polymer used in the method of the present invention may be any polymerizable liquid such as an epoxy, a catalyzed resin or a UV curable polymer, and, preferably, a UV curable polymer.
  • the epoxy may be a two-part epoxy.
  • the catalyzed resin may be an unsaturated polyester resin with a styrene monomer post-catalyzed with MEK peroxide.
  • the UV curable polymer may contain at least one acrylate-containing compound and a photoinitiator. UV curable polymers have an advantage of curing very quickly upon exposure to UV light and certain UV curable polymers are also non-yellowing upon cure.
  • first layer of the polymer, the second layer of the polymer, and the subsequent layers of the polymer according to the method of the present invention may be the same or different polymers.
  • the substrate used in the present invention may be any material which allows proper adhesion and curing of the polymer used in the method of the present invention.
  • the substrate may be, preferably, medium-density fiberboard (MDF), high-density particle board (HDPB), plywood, plastic sheet material, or glass.
  • the first layer of the polymer in an uncured form is applied to at least one surface of the substrate at a depth of about 0.5 to 80 mils and, preferably, from about 2 to 18 mils.
  • the dichroic material is deposited onto the first layer of the polymer on the resulting surface of the substrate.
  • the dichroic material may naturally migrate into the first layer of the polymer or may be otherwise immersed thereonto such as with pressure or the like.
  • the second layer of the polymer in an uncured form is applied to the resulting surface of the substrate. Once the second layer of the polymer is applied, the first layer of the polymer and the second layer of the polymer are cured. Thereafter, subsequent layers of the polymer in an uncured form may be applied to the resulting surface of the substrate and cured, as necessary, to achieve the desired effect.
  • the method of curing the polymer is dependent on the particular polymer used in the method of the present invention.
  • the first layer of the polymer and the dichroic material may be cured. Thereafter, the second layer of the polymer in an uncured form is applied to the resulting surface of the substrate and cured. Subsequent layers of the polymer in an uncured form may be applied to the resulting surface of the substrate and cured, as necessary, to achieve the desired effect.
  • the method of curing the polymer is dependent on the particular polymer used in the method of the present invention.
  • a sealer preferably, a UV curable sealer
  • the sealer is utilized, whenever necessary, to aid in the adhesion of the polymer to the substrate.
  • the particular substrate used in the method of the present invention determines the need for the sealer. After the sealer is applied to the substrate and cured under a low dose of UV radiation, the resulting surface may be sanded to aid the adhesion of the first layer of the polymer.
  • a topcoat may be applied to the resulting surface of the substrate after the first layer of the polymer, the second layer of the polymer, and the subsequent layers, where used, of the polymer are applied.
  • the topcoat is applied at a depth of about 0.1 to 10 mils and, preferably from about 3 to 18 mils, and cured to retain sheen.
  • the topcoat is, preferably, a UV curable coating which is cured under a low dose of UV radiation.
  • the topcoat may be rubbed out, if necessary, to provide the desired effect.
  • the topcoat provides durability to the surface of the substrate and aids in light refraction to make the surface of the substrate aesthetically pleasing.
  • the polymer used in the method of the present invention is a UV curable polymer.
  • the polymer may be selected from the group consisting of monoacrylates, diacrylates, triacrylates, urethane-modified acrylates, polyester-modified acrylates and mixtures thereof.
  • the polymer preferably, includes a mixture of acrylates.
  • Suitable compounds which may be used in the practice of the present invention include, but are not limited to, trimethylolpropane triacrylate, 1,6 hexane diol diacrylate, aliphatic urethane acrylates, vinyl acrylates, epoxy acrylates, ethoxylated bisphenol A diacrylates, trifunctional acrylic ester unsaturated cyclic diones, polyester diacrylates, and mixtures of the above compositions.
  • the preferred UV curable polymer is, generally, admixed with a photoinitiator.
  • Such admixture usually, comprises from about 80 to about 99.5 percent, by weight, based on the total composition weight, of the polymer; and from about 0.5 to about 15 percent, by weight, based on the total composition weight, of the photoinitiator which initiates a polymerization reaction in the composition when it is exposed to ultraviolet light.
  • the composition hereof includes from about 90 to 99.5 percent of the polymerizable compound and from about 0.5 to about 8 percent of the photoinitiator.
  • the coating composition hereof comprises 68 to 84 percent of a first diacrylate, 15 to 25 percent of a second diacrylate, and 1 to 8 percent of the photoinitiator.
  • the photoinitiator which is used in the composition of the present invention may be of the free radical or cationic type. A combination of photoinitiators may be used. Photoinitiators which are suitable for use in the practice of the present invention include, but are not limited to, l-phenyl-2-hydroxy-2-methyl-l -propanone, oligo ⁇ 2 hydroxy-2 methyl- 1- [4-(methylvinyl)phynel] propanone ⁇ , 2 hydroxy 2-methyl 1 -phenyl propan-1-one, 1- hydroxycyclohexyl phenyl ketone and benzophenone as well as mixtures thereof.
  • a preferred clear coat composition hereof comprises 65 to 85 percent ethoxylated bisphenol A diacrylate, 15 to 25 percent 1,6 hexanediol diacrylate, and 1 to 8 percent of a photoinitiator which is a mixture of oligo ⁇ 2-hydroxy-2 methyl- l-[4(methylvinyl)phenyl] propanone ⁇ and 2-hydroxy-2 methyl- 1 phenyl propan-1-one, sold commercially by Sartomer, Inc. under the mark ESACURE KP100F.
  • a preferred pigmented formula in accordance with the present invention comprises 60 to 80 percent ethyoxylated bisphenol A diacrylate, 15 to 25 percent 1,6-hexanediol diacrylate, 0.1 to 10 percent pigment solids, and 1 to 8 percent of a photoinitiator which is a mixture of oligo ⁇ 2-hydroxy- 2 methyl- l-[4(methylvinyl)phenyl] propanone ⁇ and 2-hydroxy- 2 methyl- 1 phenyl propan-1-one, sold commercially by Sartomer, Inc. under the mark ESACURE KP100F.
  • the curing of the UV curable polymer is effected by a rapid polymerization reaction which is initiated by a photoinitiator component of the composition when it is exposed to ultraviolet light, and substantially the entire composition remains in place on the substrate during and after curing.
  • the polymer of the present invention may be cured by natural sunlight, by medium pressure mercury arc lights, or by long wave ultraviolet light depending on the photoinitiator package used.
  • the UV curable polymer is, preferably, cured under a dosage of UV radiation
  • Elevated heat levels may cause the cured polymer to shrink and results in a dulling of the color-changing effect of the dichroic plastic film. Elevated heat levels may also cause the cured polymer to crack.
  • a dichroic plastic film is, preferably, used in the method of the present invention.
  • the dichroic plastic film may be wrinkled, stretched, and/or cut into shapes or particles to achieve a desired aesthetic effect.
  • the dichroic plastic film is deposited onto the first layer of the polymer.
  • the dichroic plastic film is rolled into the first layer of the polymer with, preferably, a rolling device, to remove any bubbles that may be trapped beneath the surface of the dichroic plastic film.
  • the second layer of the polymer in an uncured form is applied to the at least one surface of the substrate. Thereafter, the first layer of the polymer and the second layer of the polymer are cured.
  • Curing the first layer of the polymer and the second layer of the polymer suspends the dichroic plastic film into the polymer such that the dichroic plastic film may have peaks and valleys.
  • the subsequent layers of the polymer should be applied in an uncured form to the surface of the substrate at a depth of 0.01 to 100 mils and, preferably 3 to 10 mils, and cured until the valleys of the dichroic plastic film are filled, the surface of the substrate is smooth, and the desired effect is achieved.
  • the polymer may be either screed or raked into the valleys in the surface of the substrate with, preferably, a flat straight edge or allowed to self-level into the valleys of the dichroic plastic film.
  • the peaks of the dichroic plastic film may be finished, such as by sanding, until the surface of the substrate is level. The inside of any low spots may be manually finished to aid the adhesion of the next application of the polymer.
  • the surface on which the method of dichroic film polymerization is performed should be opaque and, preferably, black. This may be achieved in a variety of ways such as the substrate may be dyed, lacquered or painted prior to sealing.
  • the UV curable sealer may also be pigmented, however, the amount of pigment should be limited to allow adequate substrate adhesion. If the desired base color is not achieved using one of the two methods described above, a color coat may be applied in a suitable thickness to the surface of the substrate.
  • the color coat consists of any polymerizable pigmented material.
  • the color coat is a pigmented UV curable color coat which is cured under UV lamps. After the color coat is fully cured, it should be sanded to aid in the adhesion of the next coat.
  • the surface of the substrate is sanded using, preferably, a wide belt sander, to remove the uppermost peaks of the dichroic plastic film. Removing a desired number of peaks uncovers the base color of the surface of the substrate and allows the base color to provide a contrast to the color-changing nature of the dichroic plastic film.
  • the surface on which the method of dichroic film polymerization is performed may have any desired color or appearance, including metallic, pearled, and the color of the substrate.
  • the substrate is, preferably, a plastic sheet or glass.
  • the first layer of the polymer in an uncured form is applied to at least one surface of the substrate at a depth of about 0.5 to 80 mils and, preferably, from about 2 to 18 mils.
  • the dichroic material is deposited onto the first layer of the polymer on the resulting surface of the substrate.
  • the dichroic material may naturally migrate into the first layer of the polymer or may be otherwise immersed thereonto such as with pressure or the like.
  • the second layer of the polymer in an uncured form is then applied to the resulting surface of the substrate. Thereafter, an overlay, preferably, a plastic sheet or glass, is deposited on the resulting
  • a UV curable pigmented black sealer is applied to a surface of the medium-density fiberboard (MDF) and is cured under UV light at 6
  • the cured UV curable sealer is sanded with 180 grit sandpaper.
  • 6 mils of uncured UV curable polymer is applied to the sanded surface of the MDF.
  • Wrinkled dichroic plastic film is deposited on the uncured UV curable polymer and is rolled into the polymer with a roller.
  • a second layer of uncured UV curable polymer is deposited thereover and the two polymer layers are cured under an increasing voltage of UV light which ranges
  • UV curable sealer is:
  • UV curable polymer is:
  • UV curable topcoat is
  • the protective sheet is, preferably, a polycarbonate sheet laid into the wet coating and which is thereafter cured in place
  • the polycarbonate sheet bridges the contouring surface of the otherwise rough surfaces This enables obtaining of flat cured surfaces upon polymerization and reduces shrinkage
  • Polycarbonate sheets are well known and commercially available such as those sold under the mark Lexan Applying a top coat of UV curable or other curable resin to the polycarbonate sheet, after curing of the first polymer layer, yields a highly durable, dimensionally stable surface with very high gloss and few waves
  • a glass sheet may be used in lieu of the polycarbonate sheet, or a combination of a polycarbonate sheet and a glass sheet with an adhesive desposed therebetween, may be used

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Abstract

An aesthetic appearance is imparted to a substrate by depositing a curable polymeric coating composition onto the substance and depositing a dichroic material into the wet, uncured polymer. By curing the polymer and applying and curing subsequent cured polymeric layers the desired effect is achieved. Preferably, a UV-curable polymer is used although an epoxy, or a catalyzed resin may be used as the polymer.

Description

METHOD OF COATING A SUBSTRATE WITH A POLYMER HAVING A DICHROIC MATERIAL SUSPENDED THEREIN
CROSS REFERENCE TO RELATED APPLICATION
This application is a completion application of co-pending United States Provisional Application Serial Number 60/064,733 filed November 6, 1997, the disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. FIELD OF INVENTION
The present invention relates to a method of coating a substrate. More particularly, the present invention relates to a method of coating a substrate with a polymer. Even more particularly, the present invention relates to a method of coating a substrate with a polymer having a dichroic material suspended therein to create a durable, aesthetically-pleasing polymerized surface.
2. PRIOR ART
Recently, the coating art has seen the development of UV-curable coating compositions and their application to various substrates, including wood, metal, et cetera. UV-curable coating compostions exhibit many advantages over other coating compositions in their ability to cure in natural sunlight and to provide a hardened surface. Furthermore, by the addition of the appropriate adjuvants, the properties of the film can be tailored to meet the desires of the user.
Furthermore, the art has recently seen the development of sprayable, substantially solvent free, one hundred percent solids UV-curable coating compositions which are quite efficacious in usage. However, the art has yet to develop suitable means and methods for imparting aesthetic characteristics to such coatings for decorative purposes and the like. As will be detailed hereinafter, the present invention achieves this.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a method of coating a substrate which comprises:
(a) applying a first layer of a polymer in an uncured form to at least one surface of a substrate;
(b) depositing a dichroic material onto the first layer of the polymer;
(c) applying a second layer of the polymer in an uncured form to the resulting surface of the substrate;
(d) curing the first layer of the polymer and the second layer of the polymer;
(e) applying a subsequent layer of the polymer in an uncured form to the resulting surface of the substrate; and (f) curing the subsequent layer of the polymer.
In practicing the present invention the preferred polymer is a UV-curable polymer, although other polymeric compositions, such as an epoxy, a catalyzed resin or the like may be used.
The dichroic material is preferably a plastic film, although other media may be used, such as a plastic sheet, particles or glass.
For a more complete understanding of the present invention reference is made to the following detailed description and the accompanying example.
DETAILED DESCRIPTION OF THE INVENTION
As hereinabove noted, the present invention provides a method of coating a substrate with a polymer having a dichroic material suspended therein to create a durable, aesthetically-pleasing polymerized surface.
The method of coating a substrate according to the present invention comprises the steps of:
(a) applying a first layer of a polymer in an uncured form to at least one surface of a substrate;
(b) depositing the dichroic material onto the first layer of the polymer on the resulting surface of the substrate;
(c) applying a second iayer of the polymer in an uncured form to the resulting surface of the substrate;
(d) curing the first layer of the polymer and the second layer of the polymer;
(e) applying a subsequent layer of the polymer in an uncured form to the resulting surface of the substrate; and
(f) curing the subsequent layer of the polymer.
Subsequent layers of the polymer may thereafter be applied to the resulting surface of the substrate and cured, if desired, and, in as many layers as desired.
The method of the present invention provides for the use of any dichroic material which is capable of being suspended in a polymer according to the method of the present invention. A dichroic material is any material which has color-changing properties. Such dichroic materials are well known to those of ordinary skill in the art and commercially available. Any dichroic material may be used herein so long as it is inert in the polymer. Thus, the dichroic material used in the present invention may be a plastic film, a plastic sheet, particles or glass and is, preferably, a plastic film.
The polymer used in the method of the present invention may be any polymerizable liquid such as an epoxy, a catalyzed resin or a UV curable polymer, and, preferably, a UV curable polymer. The epoxy may be a two-part epoxy. The catalyzed resin may be an unsaturated polyester resin with a styrene monomer post-catalyzed with MEK peroxide. The UV curable polymer may contain at least one acrylate-containing compound and a photoinitiator. UV curable polymers have an advantage of curing very quickly upon exposure to UV light and certain UV curable polymers are also non-yellowing upon cure.
It is to be appreciated that the first layer of the polymer, the second layer of the polymer, and the subsequent layers of the polymer according to the method of the present invention may be the same or different polymers.
The substrate used in the present invention may be any material which allows proper adhesion and curing of the polymer used in the method of the present invention. The substrate may be, preferably, medium-density fiberboard (MDF), high-density particle board (HDPB), plywood, plastic sheet material, or glass.
According to the method of the present invention, the first layer of the polymer in an uncured form is applied to at least one surface of the substrate at a depth of about 0.5 to 80 mils and, preferably, from about 2 to 18 mils. Before curing the polymer, the dichroic material is deposited onto the first layer of the polymer on the resulting surface of the substrate. The dichroic material may naturally migrate into the first layer of the polymer or may be otherwise immersed thereonto such as with pressure or the like. Thereafter, the second layer of the polymer in an uncured form is applied to the resulting surface of the substrate. Once the second layer of the polymer is applied, the first layer of the polymer and the second layer of the polymer are cured. Thereafter, subsequent layers of the polymer in an uncured form may be applied to the resulting surface of the substrate and cured, as necessary, to achieve the desired effect. The method of curing the polymer is dependent on the particular polymer used in the method of the present invention.
Alternatively, once the dichroic material has been deposited as described hereinabove, the first layer of the polymer and the dichroic material may be cured. Thereafter, the second layer of the polymer in an uncured form is applied to the resulting surface of the substrate and cured. Subsequent layers of the polymer in an uncured form may be applied to the resulting surface of the substrate and cured, as necessary, to achieve the desired effect. The method of curing the polymer is dependent on the particular polymer used in the method of the present invention.
Optionally, before the application of the polymer to the substrate, a sealer, preferably, a UV curable sealer, may be directly applied to the at least one surface of the substrate. The sealer is utilized, whenever necessary, to aid in the adhesion of the polymer to the substrate. The particular substrate used in the method of the present invention determines the need for the sealer. After the sealer is applied to the substrate and cured under a low dose of UV radiation, the resulting surface may be sanded to aid the adhesion of the first layer of the polymer.
Also optional, a topcoat may be applied to the resulting surface of the substrate after the first layer of the polymer, the second layer of the polymer, and the subsequent layers, where used, of the polymer are applied. Where used, the topcoat is applied at a depth of about 0.1 to 10 mils and, preferably from about 3 to 18 mils, and cured to retain sheen. The topcoat is, preferably, a UV curable coating which is cured under a low dose of UV radiation. The topcoat may be rubbed out, if necessary, to provide the desired effect. The topcoat provides durability to the surface of the substrate and aids in light refraction to make the surface of the substrate aesthetically pleasing.
As noted, preferably, the polymer used in the method of the present invention is a UV curable polymer. The polymer may be selected from the group consisting of monoacrylates, diacrylates, triacrylates, urethane-modified acrylates, polyester-modified acrylates and mixtures thereof. The polymer, preferably, includes a mixture of acrylates. Suitable compounds which may be used in the practice of the present invention include, but are not limited to, trimethylolpropane triacrylate, 1,6 hexane diol diacrylate, aliphatic urethane acrylates, vinyl acrylates, epoxy acrylates, ethoxylated bisphenol A diacrylates, trifunctional acrylic ester unsaturated cyclic diones, polyester diacrylates, and mixtures of the above compositions. The preferred UV curable polymer is, generally, admixed with a photoinitiator. Such admixture, usually, comprises from about 80 to about 99.5 percent, by weight, based on the total composition weight, of the polymer; and from about 0.5 to about 15 percent, by weight, based on the total composition weight, of the photoinitiator which initiates a polymerization reaction in the composition when it is exposed to ultraviolet light.
More preferably, the composition hereof includes from about 90 to 99.5 percent of the polymerizable compound and from about 0.5 to about 8 percent of the photoinitiator.
In a preferred embodiment hereof, the coating composition hereof comprises 68 to 84 percent of a first diacrylate, 15 to 25 percent of a second diacrylate, and 1 to 8 percent of the photoinitiator.
The photoinitiator which is used in the composition of the present invention may be of the free radical or cationic type. A combination of photoinitiators may be used. Photoinitiators which are suitable for use in the practice of the present invention include, but are not limited to, l-phenyl-2-hydroxy-2-methyl-l -propanone, oligo {2 hydroxy-2 methyl- 1- [4-(methylvinyl)phynel] propanone}, 2 hydroxy 2-methyl 1 -phenyl propan-1-one, 1- hydroxycyclohexyl phenyl ketone and benzophenone as well as mixtures thereof.
A preferred clear coat composition hereof comprises 65 to 85 percent ethoxylated bisphenol A diacrylate, 15 to 25 percent 1,6 hexanediol diacrylate, and 1 to 8 percent of a photoinitiator which is a mixture of oligo {2-hydroxy-2 methyl- l-[4(methylvinyl)phenyl] propanone} and 2-hydroxy-2 methyl- 1 phenyl propan-1-one, sold commercially by Sartomer, Inc. under the mark ESACURE KP100F.
A preferred pigmented formula in accordance with the present invention comprises 60 to 80 percent ethyoxylated bisphenol A diacrylate, 15 to 25 percent 1,6-hexanediol diacrylate, 0.1 to 10 percent pigment solids, and 1 to 8 percent of a photoinitiator which is a mixture of oligo {2-hydroxy- 2 methyl- l-[4(methylvinyl)phenyl] propanone} and 2-hydroxy- 2 methyl- 1 phenyl propan-1-one, sold commercially by Sartomer, Inc. under the mark ESACURE KP100F.
The curing of the UV curable polymer is effected by a rapid polymerization reaction which is initiated by a photoinitiator component of the composition when it is exposed to ultraviolet light, and substantially the entire composition remains in place on the substrate during and after curing.
The polymer of the present invention may be cured by natural sunlight, by medium pressure mercury arc lights, or by long wave ultraviolet light depending on the photoinitiator package used. The UV curable polymer is, preferably, cured under a dosage of UV radiation
2 2 which, preferably, ranges between 0.5 joules/cm to 7 joules/cm , to reduce the likelihood of elevated heat levels. Elevated heat levels may cause the cured polymer to shrink and results in a dulling of the color-changing effect of the dichroic plastic film. Elevated heat levels may also cause the cured polymer to crack.
As noted above, a dichroic plastic film is, preferably, used in the method of the present invention. The dichroic plastic film may be wrinkled, stretched, and/or cut into shapes or particles to achieve a desired aesthetic effect. After the first layer of the polymer has been applied to the at least one surface of the substrate, the dichroic plastic film is deposited onto the first layer of the polymer. Preferably, the dichroic plastic film is rolled into the first layer of the polymer with, preferably, a rolling device, to remove any bubbles that may be trapped beneath the surface of the dichroic plastic film. Once the desired bubbles are removed, the second layer of the polymer in an uncured form is applied to the at least one surface of the substrate. Thereafter, the first layer of the polymer and the second layer of the polymer are cured.
Curing the first layer of the polymer and the second layer of the polymer suspends the dichroic plastic film into the polymer such that the dichroic plastic film may have peaks and valleys. As such, the subsequent layers of the polymer should be applied in an uncured form to the surface of the substrate at a depth of 0.01 to 100 mils and, preferably 3 to 10 mils, and cured until the valleys of the dichroic plastic film are filled, the surface of the substrate is smooth, and the desired effect is achieved.
To provide a superior surface, after each application of the polymer in uncured form to the surface of the substrate, the polymer may be either screed or raked into the valleys in the surface of the substrate with, preferably, a flat straight edge or allowed to self-level into the valleys of the dichroic plastic film. Once each application of the polymer is cured, the peaks of the dichroic plastic film may be finished, such as by sanding, until the surface of the substrate is level. The inside of any low spots may be manually finished to aid the adhesion of the next application of the polymer.
To achieve the most vivid color-changing effect from the suspension of the dichroic plastic film in the polymer, the surface on which the method of dichroic film polymerization is performed should be opaque and, preferably, black. This may be achieved in a variety of ways such as the substrate may be dyed, lacquered or painted prior to sealing. The UV curable sealer may also be pigmented, however, the amount of pigment should be limited to allow adequate substrate adhesion. If the desired base color is not achieved using one of the two methods described above, a color coat may be applied in a suitable thickness to the surface of the substrate. The color coat consists of any polymerizable pigmented material.
Preferably, the color coat is a pigmented UV curable color coat which is cured under UV lamps. After the color coat is fully cured, it should be sanded to aid in the adhesion of the next coat.
After full cure of the first application of the polymer, the surface of the substrate is sanded using, preferably, a wide belt sander, to remove the uppermost peaks of the dichroic plastic film. Removing a desired number of peaks uncovers the base color of the surface of the substrate and allows the base color to provide a contrast to the color-changing nature of the dichroic plastic film.
It is to be appreciated that the surface on which the method of dichroic film polymerization is performed may have any desired color or appearance, including metallic, pearled, and the color of the substrate.
Optionally, the substrate is, preferably, a plastic sheet or glass. The first layer of the polymer in an uncured form is applied to at least one surface of the substrate at a depth of about 0.5 to 80 mils and, preferably, from about 2 to 18 mils. Before curing the polymer, the dichroic material is deposited onto the first layer of the polymer on the resulting surface of the substrate. The dichroic material may naturally migrate into the first layer of the polymer or may be otherwise immersed thereonto such as with pressure or the like. The second layer of the polymer in an uncured form is then applied to the resulting surface of the substrate. Thereafter, an overlay, preferably, a plastic sheet or glass, is deposited on the resulting
2 surface of the substrate and cured under UV light at about .5 joules/cm to about 10
2 joules/cm .
Following is an illustrative example where all parts are by weight absent contrary indications.
EXAMPLE I
At ambient temperature and pressure a UV curable pigmented black sealer is applied to a surface of the medium-density fiberboard (MDF) and is cured under UV light at 6
2 joules/cm . The cured UV curable sealer is sanded with 180 grit sandpaper. Next, 6 mils of uncured UV curable polymer is applied to the sanded surface of the MDF. Wrinkled dichroic plastic film is deposited on the uncured UV curable polymer and is rolled into the polymer with a roller. Then, a second layer of uncured UV curable polymer is deposited thereover and the two polymer layers are cured under an increasing voltage of UV light which ranges
2 2 from .5 joules/cm to 7 joules/cm . After full cure, the top peaks of the dichroic plastic film are sanded off with a wide belt sander. The valleys of the dichroic plastic film are then manually sanded. The dust is blown off and another layer of uncured polymer is applied to the resulting surface of the MDF. The uncured polymer is raked into the valleys of the dichroic plastic film and is then cured. The uncured polymer is then repeatedly applied, raked into any valleys of the dichroic plastic film, and cured until the surface of the MDF is
2 smooth. Then 4 mils of topcoat is applied and UV cured at 6 joules/cm . Herein the UV curable sealer is:
Parts fr v weight aliphatic urethane acrylate 25.0 epoxy acrylate 12.5 isobornyl acrylate 25.0 aliphatic trifunctional acrylate 33.0 photoinitiator 4.5
100.0
To the above composition, 3 parts black pigment is added to prepare the UV curable sealer pigmented black.
Herein the UV curable polymer is:
Parts by weight
aliphatic urethane acrylate 25.0 epoxy acrylate 12 5 isobornyl acrylate 25 0 aliphatic trifunctional acrylate 33 0 photoinitiator 4 5
100 0
Herein, the UV curable topcoat is
Parts b' v weight
aliphatic urethane acrylate 30 0 epoxy acrylate 15 0 isobornyl acrylate 35 0 aliphatic trifunctional acrylate 15 0 acrylated silicone 75 photoinitiator 4 25
100 00
It has also been found in practicing the present invention that subsequent to the application of the dichroic material on the first layer of polymer it is possible to deposit thereover a protective layer such as a Thermoplastic sheet Where used, the protective sheet is, preferably, a polycarbonate sheet laid into the wet coating and which is thereafter cured in place The polycarbonate sheet bridges the contouring surface of the otherwise rough surfaces This enables obtaining of flat cured surfaces upon polymerization and reduces shrinkage Polycarbonate sheets are well known and commercially available such as those sold under the mark Lexan Applying a top coat of UV curable or other curable resin to the polycarbonate sheet, after curing of the first polymer layer, yields a highly durable, dimensionally stable surface with very high gloss and few waves
Similarly, a glass sheet may be used in lieu of the polycarbonate sheet, or a combination of a polycarbonate sheet and a glass sheet with an adhesive desposed therebetween, may be used
Having , thus, described the invention what is claimed is

Claims

I . A method of coating a substrate which comprises the steps of:
(a) applying a first layer of a first polymer in an uncured form to at least one surface of a substrate;
(b) depositing a dichroic material onto the first layer of the polymer substrate;
(c) applying a second layer of a second polymer in an uncured form to the resulting surface of the substrate;
(d) curing the first layer of polymer and the second layer of polymer;
2. The method of Claim 1 which further comprises:
(a) applying a subsequent layer of a third polymer in an uncured form to the resulting surface of the substrate; and
(b) curing the subsequent layer of polymer.
3. The method of Claim 1 wherein the first, second and third polymers are the same.
4. The method of Claim 3 wherein the polymer is a UV-curable polymer.
5. The method of Claim 3 wherein the polymer is a substantially one hundred percent solid UV-curable polymer.
6. The method of Claim 1 wherein at least one of the first, the second or the third polymer is a UV-curable polymer.
7. The method of Claim 6 wherein the UV-curable polymer is a substantially one hundred percent solid UV-curable polymer.
8. The method of Claim 1 which further comprises: depositing a protective layer which is either a thermoplastic sheet, a glass sheet or a combination of a thermoplastic and a glass sheet over the dichroic material.
9. The method of Claim 8 wherein the thermoplastic material is a polycarbonate.
10. The method of Claim 1 wherein: the substrate is an opaque substrate.
I I . The method of Claim 1 which further comprises: depositing a top coat of a fourth curable polymer over each cured polymer layer.
PCT/US1998/023257 1998-11-06 1998-11-06 Method of coating a substrate with a polymer having a dichroic material suspended therein WO2000027545A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU14504/99A AU1450499A (en) 1998-11-06 1998-11-06 Method of coating a substrate with a polymer having a dichroic material suspended therein

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US6473398P 1998-11-06 1998-11-06
US60/064,733 1998-11-06

Publications (1)

Publication Number Publication Date
WO2000027545A1 true WO2000027545A1 (en) 2000-05-18

Family

ID=22057946

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Country Status (2)

Country Link
AU (1) AU1450499A (en)
WO (1) WO2000027545A1 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1447146A1 (en) * 2003-02-12 2004-08-18 Deceuninck NV Method for coating a surface, especially a plastic profile and coated plastic profile
US9678258B2 (en) 2009-12-17 2017-06-13 Apple Inc. Dichroic glass for cosmetic appeal in an electronic device

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS57169750A (en) * 1981-04-13 1982-10-19 Nippon Telegr & Teleph Corp <Ntt> Method for color development of two color recording medium
US5051309A (en) * 1989-04-27 1991-09-24 Mitsubishi Gas Chemical Co., Inc. Anti-dazzling polycarbonate polarizing plate

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS57169750A (en) * 1981-04-13 1982-10-19 Nippon Telegr & Teleph Corp <Ntt> Method for color development of two color recording medium
US5051309A (en) * 1989-04-27 1991-09-24 Mitsubishi Gas Chemical Co., Inc. Anti-dazzling polycarbonate polarizing plate

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1447146A1 (en) * 2003-02-12 2004-08-18 Deceuninck NV Method for coating a surface, especially a plastic profile and coated plastic profile
BE1015357A5 (en) * 2003-02-12 2005-02-01 Deceuninck N V COLD pigmentation.
US9678258B2 (en) 2009-12-17 2017-06-13 Apple Inc. Dichroic glass for cosmetic appeal in an electronic device
US11885994B2 (en) 2009-12-17 2024-01-30 Apple Inc. Dichroic glass for cosmetic appeal in an electronic device

Also Published As

Publication number Publication date
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