Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Physical dimension specified
Reexamination Certificate
1998-05-18
2002-06-25
Nakarani, D. S. (Department: 1773)
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Physical dimension specified
C428S031000, C428S424200, C428S424400, C428S424800, C428S425800, C428S425900, C428S450000
Reexamination Certificate
active
06410131
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to flexible lustered products used, for example, as automobile radiator grilles. More particularly, the present invention relates to flexible lustered products having a base material formed from flexible resin and a surface with metallic luster.
2. Brief Description of the Related Art
As shown in
FIG. 9
, a typical flexible lustered product
51
includes a base material
52
, which is formed from a material such as polyurethane, a base coat layer
53
, which is a coating applied to the base material
52
, a metal film layer
54
, which is applied to the base coat layer
53
, and a top coat layer
55
, which is applied to the metal film layer
54
. The base coat layer
53
has a mirror smooth surface to enable satisfactory application of the film layer
54
. The top coat layer
55
protects the film layer
54
.
The metal film layer
54
is formed from a continuous film that results in several problems. For example, the
25
application of an external force to the lustered product
51
may result in distortion or deformation of the product
51
. Among the elements constituting the lustered product
51
, the base material
52
, the base coat layer
53
, and the top coat layer
55
restore their original form after the application
30
of the external force. However, since the film layer
54
is made of a single sheet of metal film, it cannot tolerate as much deformation. As shown in
FIG. 10
, when the lustered product
51
is deformed by a large external force (arrow
57
), the film layer
54
cannot follow the deformation of the base material
52
and the layers
53
,
55
. Thus, a relatively large stress acts on the film layer
54
. This may form cracks
56
in the film layer
54
. The cracks
56
appear as white streaks and thus deteriorate the appearance of the lustered product
51
.
Japanese Unexamined Patent Publication No. 9-70920 describes a metal film layer that solves the above problems. The metal film layer is made of an anticorrosive metal and has a thickness that is at least 150 Å and at most 180 Å. The metal film layer also has grain boundaries.
When an external force acts on the flexible lustered product of Publication No. 9-70920, the base material, which is made of a flexible resin material, the base coat layer, and the top coat layer deform in accordance with the external force. The fine metal particles forming the metal film layer are visually perceived as a metal film having a uniform surface. However, due to the grain boundaries of the metal film layer, the application of an external force just moves adjacent crystal grains (metal grains) apart from each other and widens the distance between the crystal grains. This suppresses the formation of cracks and prevents deterioration of the appearance of the product. In addition, the anticorrosive property of the film layer prevents corrosion.
However, the metal film layer of the above publication
30
is still problematic in that the adhesion of the metal film layer to the base coat layer and the top coat layer is insufficient. This is because the base coat layer and the top coat layer are made of a resin material. Therefore, when the lustered product is used under harsh conditions or over a long period of time, the base coat layer and the top coat layer may peel off the metal film layer.
When a flexible lustered product is employed, for example, on the exterior of an automobile, paint is often applied to the top coat layer. In such case, the solvent included in the paint may cause swelling of the top coat layer. If the level of swelling becomes high, the adhesiveness between the metal film layer and the base coat layer becomes further insufficient. This may also result in the top coat layer peeling off the metal film layer.
SUMMARY OF THE INVENTION
Accordingly, it is an objective of the present invention to provide a flexible lustered product that prevents cracks from forming in its metal film layer, prevents deterioration of the quality of the outer appearance, and prevents peeling between its layers.
To achieve the above objective, the present invention provides a flexible lustered product including a base material made of resin. A base coat layer is formed on at least a portion of a surface of the base material by applying a coating. The base coat layer has a glass transition point that is at least −30° C. and at most 0° C. The base coat layer includes a silane coupling agent having a mercapto group. A metal film layer is applied to at least a portion of a surface of the base coat layer. The metal film layer is anticorrosive and has a thickness that is at least 150 Å and at most 800 Å. The metal film layer is formed by a plurality of metal particles disposed in contact with one another so as to define a grain boundary between adjacent metal particles. A top coat layer is formed on at least a portion of a surface of the metal film layer by applying a coating.
A further aspect of the present invention provides a flexible lustered product including a base material made of resin. A base coat layer is formed on at least a portion of a surface of the base material by applying a coating. A metal film layer is applied to at least a portion of a surface of the base coat layer. The metal film layer is anticorrosive and has a thickness that is at least 150 Å and at most 800 Å. The metal film layer is formed by a plurality of metal particles disposed in contact with one another to define a grain boundary between adjacent metal particles. A top coat layer is formed on at least a portion of a surface of the metal film layer by applying a coating. The top coat layer has a swelling rate of at least 100% and at most 150%. Furthermore, the top coat layer includes a silane coupling agent having a mercapto group.
Another aspect of the present invention provides a flexible lustered product including a base material made of resin. A base coat layer is formed on at least a portion of a surface of the base material by applying a coating. The base coat layer has a glass transition point that is at least −30° C. and at most 0° C. The base coat layer includes a silane coupling agent having a mercapto group. A metal film layer is applied to at least a portion of a surface of the base coat layer. The metal film layer is anticorrosive and has a thickness that is at least 150 Å and at most 800 Å. The metal film layer is formed by a plurality of metal particles disposed in contact with one another so as to define a grain boundary between adjacent metal particles. A top coat layer is formed on at least a portion of a surface of the metal film layer by applying a coating. The top coat layer has a swelling rate of at least 100% and at most 150%. The top coat layer also includes a silane coupling agent having a mercapto group.
Other aspects and advantages of the present invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
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patent: 4101698 (1978-07-01), Dunning et al.
patent: 4369225 (1983-01-01), Manabe
patent: 4407871 (1983-10-01), Eisfeller
patent: 4431711 (1984-02-01), Eisfeller
patent: 4713143 (1987-12-01), Eisfeller
patent: 4931366 (1990-06-01), Mullaney, Jr.
patent: 4935275 (1990-06-01), Ushida et al.
patent: 5624759 (1997-04-01), Usifer et al.
patent: 0 751 235 (1997-01-01), None
patent: 57-12637 (1982-01-01), None
patent: 2-286328 (1990-11-01), None
patent: 7-323260 (1995-12-01), None
patent: 9-70920 (1997-03-01), None
patent: 9-74273 (1997-03-01), None
WPIDS on STN. Derwent Information Ltd. accessed on Jul. 26, 1999 JP 07-6624 A, Jan. 10, 1995.
WPIDS on STN. Derwent Information Ltd., accessed on Jul 26, 1999. JP 01-268777A, Oct. 16, 1989.
Hasegawa Yukitaka
Kawazu Kenji
Nishimoto Sonoko
Ogisu Yasuhiko
Nakarani D. S.
Pillsbury & Winthrop LLP
Toyoda Gosei Co,., Ltd.
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