Stock material or miscellaneous articles – Composite – Of polycarbonate
Reexamination Certificate
1999-11-12
2002-04-02
Kiliman, Leszek (Department: 1773)
Stock material or miscellaneous articles
Composite
Of polycarbonate
C428S421000, C428S457000, C428S458000, C428S461000, C428S463000, C427S318000, C427S377000, C427S409000
Reexamination Certificate
active
06365276
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to novel coated metal articles, in particular coated, untreated, bright, sealed, anodized metal sheets, especially coated bright, sealed, anodized aluminum sheets. The present invention also relates to methods for coating metal articles, in particular untreated, bright, sealed, anodized metal sheets, especially bright, sealed, anodized aluminum sheets. The present invention further relates to laminated composites which contain such a coated metal article, and methods for preparing such laminated composites.
2. Discussion of the Background
Unsealed metal substrates which have been anodized by an electrochemical process employing sulfuric acid, chromic acid, phosphoric acid, or oxalic acid electrolytes, provide an excellent base for adhesion of a paint, enamel or lacquer coating because of the porosity of the anodized metal surface. Clear methacrylate lacquers are known to be useful to paint such unsealed, anodized metal surfaces to provide a high gloss coating.
However, anodized metal substrates are often sealed when it is desired to employ the metal in an environment where the porosity of the anodized metal is undesirable, such as for example when used in auto trim parts where exposure to the elements can result in corrosion or staining of the metal. Sealing of such anodized metal substrates, such as by immersion in boiling deionized water, sodium bichromate, nickel acetate solutions, or steam, makes the anodized coating on the metal nonabsorptive by closing down or plugging the pore structure of the anodized coating. When anodized metal substrates have been sealed, it is very difficult for paint or a coating to adhere to the surface of the sealed, anodized metal substrate, particularly untreated bright, sealed, anodized metal substrates, even more particularly untreated, bright, sealed, anodized aluminum substrates.
U.S. Pat. No. 5,178,915 discloses the coating of untreated, bright, sealed anodized metals such as aluminum coils, with a catalyst-free coating composition, which contains a high gloss, thermosetting, hydroxyl group-containing fluorocarbon polymer (such as a fluorinated ethylene vinyl ether, FEVE), a crosslinking agent, a solvent, an ultraviolet screening agent, and an ultraviolet stabilizer. However, the coating of U.S. Pat. No. 5,178,915 specifically excludes inclusion of a catalyst to impart the necessary properties. In addition, U.S. Pat. No. 5,178,915 uses very high temperatures (>450° F.) both for the coil coating and curing processes.
U.S. Pat. No. 5,366,803 discloses metal sheets having a layer of cured polyvinylidene fluoride (PVDF) paint on the metal surface and a layer of cured FEVE on the cured layer of PVDF and laminated composites prepared from such metal sheets. However, it is desirable that coatings provide a mirrored finish with a high gloss, i.e. produce at least 99 percent reflectance, and the coatings of U.S. Pat. No. 5,366,803 have a gloss of only 25 to 80%.
Various composite laminates are known wherein a metal sheet is laminated on a thermoplastic synthetic resin sheet. U.S. Pat. No. 4,508,425 discloses a mirror manufactured by plating chromium on one surface of a metal sheet which bonded to a synthetic resin sheet, to form a mirror surface. The mirrored-finish sheet may be worked to a desired shape and may be formed with a decorative pattern U.S. Pat. No. 4,560,623 discloses a specular product of bronze-like tone particularly suitable for use as a decorative material. The specular product uses, as a substrate, a composite comprising a synthetic resin sheet and metal sheets laminated thereon, and includes a nickel deposit plated on the metal sheet and a specular film of Sn—Ni alloy electroplated on the nickel deposit using a specific electroplating bath.
Such laminates are useful for a number of architectural applications, because the laminates combine light weight with high strength. These laminates may be used as finished surfaces for all or some portions of the interior or exterior surfaces of a building.
However, when metal sheets are coated with conventional polyvinylidene fluoride (PVDF) paints, the coated plates exhibit a phenomenon known as heat blocking upon subsequent lamination with a resin layer. This heat blocking phenomenon seriously detracts from the aesthetic appeal of the finished plate. In addition, use of conventional PVDF paints results in coatings which have a gloss within a fairly narrow range, 25 to 35%.
Thus, there remains a need for coated metal articles, in particular coated untreated, bright, sealed, anodized metal sheets, especially coated bright, sealed, anodized aluminum sheets, which overcome the above-described deficiencies. There also remains a need for coated metal sheets with a high degree of gloss or reflectance, which do not experience heat blocking on lamination, which exhibit excellent weathering resistance, and which are able to be bent to a sharp angle without cracking of the coating on the exposed metal surface. There also remains a need for laminates which contain such a coated metal sheet. There also remains a need for methods for preparing such coated metal articles and such laminates.
SUMMARY OF THE INVENTION
Thus, it is one object of the present invention to provide novel coated metal articles.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized metal sheets.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized metal sheets in coil form.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized aluminum sheets.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized aluminum sheets in coil form.
It is another object of the present invention to provide novel coated metal articles, which exhibit a high gloss.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized metal sheets, which exhibit a high gloss.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized metal sheets, which exhibit a high gloss, in coil form.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized aluminum sheets, which exhibit a high gloss.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized aluminum sheets, which exhibit a high gloss, in coil form.
It is another object of the present invention to provide novel coated metal articles, which exhibit a high reflectance.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized metal sheets, which exhibit a high reflectance.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized metal sheets, which exhibit a high reflectance, in coil form.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized aluminum sheets, which exhibit a high reflectance.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized aluminum sheets, which exhibit a high reflectance, in coil form.
It is another object of the present invention to provide novel coated metal articles, which exhibit a reflectance of at least 87% or a gloss rating of at least 99%.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized metal sheets, which exhibit a reflectance of at least 87% or a gloss rating of at least 99%.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized metal sheets, which exhibit a reflectance of at least 87% or a gloss rating of at least 99%, in coil form.
It is another object of the present invention to provide novel coated untreated, bright, sealed, anodized aluminum sheets, which exhibit a reflectance of at least 87% or
Chapman Frederick L.
Harford Richard N.
Menon Hari
Rudisi Joseph J.
Sonoda Tetsu
Kiliman Leszek
Mitsushita Chemical America, Inc.
Oblon & Spivak, McClelland, Maier & Neustadt P.C.
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