Stock material or miscellaneous articles – Structurally defined web or sheet – Discontinuous or differential coating – impregnation or bond
Reexamination Certificate
1999-11-01
2001-05-29
Evans, Elizabeth (Department: 1774)
Stock material or miscellaneous articles
Structurally defined web or sheet
Discontinuous or differential coating, impregnation or bond
C428S201000, C428S203000, C428S457000, C428S458000
Reexamination Certificate
active
06238776
ABSTRACT:
TECHNICAL FIELD
This invention pertains to vacuum deposition of amphoteric materials.
BACKGROUND OF THE INVENTION
Vacuum metallizing of plastic and similar dielectric substrates is disclosed in various forms including U.S. Patents:
2,992,125
Fustier
2,993,806
Fisher
3,118,781
Downing
3,914,472
Nakanishi
4,101,698
Dunning
4,131,530
Blum
4,211,822
Kurfman
4,215,170
Oliva
In addition, two reference books are:
Thin Film Phenomena
, Kasturi L. Chopra, Robert E. Kreiger Publishing Company, Huntington, N.Y., 1979. pp. 163-189.
Handbook of Thin Film Technology
, Leon I. Maissel and Reinhard Glang, McGraw-Hill Book Company, New York, N.Y., 1970., pp. 8-32 to 8-43.
U.S. Pat. Nos. 4,407,871, 4,431,711 and 4,713,143, assigned to assignee of the present invention and incorporated herein by reference, relate to metallizing of plastic articles and more particularly to the structure and spacing of discrete metal islands used to metallize rather than a continuous metal film. The metallizing is performed utilizing the island coating system as detailed in the aforesaid patents. The system includes generally spray depositing sequentially a primer coating layer, a basecoat coating layer, a metallizing layer and a topcoat layer. As disclosed in the above referenced patents, the coating layers contain non-volatile film forming polymers, generally in the range of 10-30% requiring flash time of 20 minutes at ambient temperature and cure times of approximately 30 minutes at 260° F. between application of layers.
In addition to proper deposition of the coating layers, the appearance and performance of the commercial product, the conductivity of the metal layer, the corrosion resistance of the metal layer and/or the adhesion of the top coat all relate to the structure and spacing of the islands. The above referenced patents provide further teachings related to nucleation and film growth to the desired island structure and spacing that achieves these ends.
In U.S. Pat. No. 5,290,625, assigned to the assignee of the present invention and incorporated herein by reference, the above process is applied to aluminum parts. In a co-pending application, U.S. Ser. No. 08/248,957, assigned to the assignee of the present invention and incorporated herein by reference, the coating layers are modified to form a combined primer/basecoat layer. The underlying combined primer/basecoat can include a pigment to provide a colored metallic appearance as disclosed in U.S. Pat. No. 5,320,869 issued Jun. 14, 1994 and assigned to assignee of the present invention and incorporated herein by reference. In another co-pending application, U.S. Ser. No. 08/248,649, assigned to the assignee of the present invention and incorporated herein by reference, the technology for coating layer deposition is improved to allow film builds of 1.5 to 2.0 mils, eliminating significant coating irregularities.
The current island coating system spray deposits the polymeric constituents of the primer layer, basecoat layer and topcoat layer in organic solvent carriers such as glycol ethers, glycolether acetates, aromatic hydrocarbons and dibasic esters. These solvent carriers pose a waste disposal problem increasing the cost of production significantly, a flammability hazard, as well as requiring significant flash and cure times. If the organic solvents could be eliminated, while still maintaining the aesthetic properties of the metallized appearance, significant savings in time and therefore increased production, improved safety, as well as ease of waste disposal would be attained. Additionally, with the elimination of organic solvents the range of substrates that can be metallized could be increased.
In general, the step of spray depositing is done for batch processing while the parts are being rotated as described in U.S. Pat. No. 5,284,679 issued Feb. 8, 1994 and assigned to the assignee of the present invention, and incorporated herein by reference. However, the use of rotation is not practical when dealing with substrates that are thin sheets such as thin extruded polymers, cellulose based materials and textiles. These thin gauge sheets or sheetstocks require different handling and for high speed production it would be useful to be able to have continuous in-line processing.
Apparel designers would find it advantageous to have a metallized sheetstock made from various materials such as polymers, vinyls, cellulose based materials and textiles, that are flexible, washable, formable, and die cutable. Currently available metallic trims are generally either not truly metallic in appearance, or upon washing and wetting lose metallic luster or cannot be washed at all. Further, it would be advantageous to have materials with a metallized appearance that can be “ironed on”, i.e. a thermal bonding adhesive, in addition to “stitched on”. As one example, athletic shoe manufacturers have a perceived need to individualize their products with unique, identifiable features, as for example lights that are present on one brand of athletic shoes. Metallic trim would be useful in creating such identifiable features.
It would be useful to have thin polymer extrusion metallic finish products that can be cut on high speed electrically resisted die blades without arcing. Further it would be useful to be able to utilize such materials as exterior trim without corrosion and which can be used for in-mold decorating and which have the proper reflectivity or depth of image.
SUMMARY OF THE INVENTION AND ADVANTAGES
According to the present invention, a process for manufacturing a metallized substrate using the island coating system, includes depositing a first coating layer containing a radiation curable non-volatile film former. The coated substrate is then vacuum metallized to form the metal islands of the present invention and a layer of clear resinous protective dielectric topcoat containing a radiation curable non-volatile film former is deposited to completely cove r the layer of metal islands while maintaining the aesthetic properties of the metallizing island coating system at a reduced cost and with minimal variability.
The substrate can be formed parts of various polymers or metals or the substrate can be a sheetstock made from materials such as a thin gauge extruded polymer, vinyl, textile or cellulose based material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides a process of manufacturing substrates/parts, and the manufactured parts/substrates themselves, that have a metallized appearance, that reduces the amount of organic wastes and production time as well as allowing continuous in-line processing of sheetstock utilizing the island coating system.
The part can be made from a substrate material selected from the group comprising crystalline and/or amorphous thermoplastic elastomers such as thermoplastic urethanes, thermoplastic urethane alloys, polyester alloys, thermoplastic olefins, polyamide alloys and metals such as aluminum, magnesium and steel.
Further the substrate material can be in a thin gauge sheet form, i.e. sheetstock. The sheetstock has a thickness range of from 0.002 inches to 2 inches with 0.002 to 0.5 inches being the preferred range. The sheetstock can also include textiles such as, but not limited to, cotton, denim, canvas as well as vinyls and cellulose based materials including rayon.
In-line processing refers to a process wherein the material being treated is moved from one holding means and taken up by another and while moving between is treated by the process. For example, reel-to-reel processing would be one means of in-line processing.
The island coating system is then applied as taught in U.S. Pat. Nos. 4,407,871, 4,431,711, 4,713,143, 5,290,625 with the improvements disclosed in the present invention. The island coating system includes generally as a first coating layer either a combined primer/basecoat layer, or separately applied primer and basecoat layers, a metallizing layer and an encapsulating topcoat layer. The prior art teaches that each coating layer contains film forming polymers as disclosed
Clark John B.
Dukeshire Mark E.
Eisfeller Richard C.
Finch Richard W.
Lein Maureen M.
Davidson Textron Inc.
Evans Elizabeth
Hayes, Soloway, Hennessey Grossman & Hage, P.C.
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