SELF-CLEANING SUBSTRATES AND METHODS FOR MAKING THE SAME

• US 20110027485A1
• Filed: 09/29/2009
• Published: 02/03/2011
• Est. Priority Date: 08/03/2009
• Status: Active Grant

• Current Assignee: Arconic Technologies LLC (Arconic Corp.)
• Original Assignee: Alcoa Incorporated (Howmet Aerospace, Inc.)
• Inventors: Askin, Albert L., Skiles, Jean Ann, Kolek, Paula L., Biehlmann, Yves, Belnap, Craig, Bell, James, Keener, John, Nintzel, Grant, Zediak, Clinton, Kahn, Jay A.
• Granted Patent: US 8,617,665 B2
• Time in Patent Office: Days
• US Class Current: 427/331
• CPC Class Codes: B05D 1/28 performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
• CPC Class Codes: B05D 2202/25 based on Al
• CPC Class Codes: B05D 5/08 to obtain an anti-friction or anti-adhesive surface rendering particulate materials free-flowing in general, e.g. making them hydrophobic B01J2/30
• CPC Class Codes: B05D 7/56 Three layers or more
• CPC Class Codes: C09D 5/1618 inorganic
• CPC Class Codes: C09D 5/1693 as part of a multilayer system
• CPC Class Codes: C23C 26/00 Coating not provided for in groups C23C2/00 - C23C24/00
• CPC Class Codes: C23C 28/00 Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D

Abstract

A methods, apparatus and compositions for producing colored, self-cleaning substrates by roll coating are provided. The roll coated, colored, self-cleaning substrates retain the predetermined color and a predetermined gloss of the colored coating, thereby facilitating their use in architectural applications. The roll coated, colored, self-cleaning substrates may be iridescent-free.

Claims

1. A method comprising:

(a) first producing a colored aluminum sheet product having a predetermined color and a predetermined gloss, the first producing step comprising;

(i) roll coating a colored coating onto an aluminum alloy sheet; and

(ii) converting the colored coating into a colored layer, wherein the colored layer is located on an outer surface of the aluminum alloy sheet;

(b) second producing an intermediate aluminum sheet product, the second producing step comprising;

(i) roll coating a barrier coating onto at least a portion of the colored layer of the colored aluminum sheet product; and

(ii) converting the barrier coating into a barrier layer, wherein, after the converting step, the barrier layer is located on at least a portion of the colored layer;

wherein, after the second converting step, the intermediate aluminum sheet product retains the predetermined color and retains the predetermined gloss of the colored aluminum sheet product; and

(c) third producing a colored self-cleaning aluminum sheet product, the third producing comprising;

(i) roll coating a self-cleaning coating onto at least a portion of the barrier layer of the intermediate aluminum sheet product; and

(ii) converting the self-cleaning coating into a self-cleaning layer, wherein, after the converting step, the self-cleaning layer is on at least a portion of the barrier layer;

wherein, the colored self-cleaning aluminum sheet product retains the predetermined color and retains the predetermined gloss of the colored aluminum sheet product.

2. The method of claim 1, wherein the second producing and the third producing steps are completed in sequence and in a single roll coating unit.

3. The method of claim 1, wherein the first producing, the second producing and the third producing are completed in sequence and in a single roll coating unit.

4. The method of claim 1, wherein the barrier coating comprises silica.

5. The method of claim 1, wherein the self-cleaning coating is surfactant-free.

6. The method of claim 1, wherein the self-cleaning coating comprises titanium dioxide.

7. The method of claim 1, wherein the colored self-cleaning aluminum sheet product has a Delta E that is not greater than about 10 as compared to the colored aluminum sheet product.

8. The method of claim 1, wherein the colored self-cleaning aluminum sheet product has a Delta-E that is not greater than about 5 as compared to the colored aluminum sheet product.

9. The method of claim 1, wherein the colored self-cleaning aluminum sheet product has a Delta-E that is not greater than about 1 as compared to the colored aluminum sheet product.

10. The method of claim 1, wherein the colored self-cleaning aluminum sheet product has a gloss that is not greater than about 20 units different than the gloss of the colored aluminum sheet product.

11. The method of claim 1, wherein the colored self-cleaning aluminum sheet product has a gloss that is not greater than about 10 units than the gloss of the colored aluminum sheet product.

12. The method of claim 1, wherein the colored self-cleaning aluminum sheet product has a gloss that is not greater than about 5 units different than the gloss of the colored aluminum sheet product.

13. The method of claim 1, wherein the colored self-cleaning aluminum sheet product has a gloss that is not greater than about 1 unit different than the gloss of the colored aluminum sheet product.

14. The method of claim 1, wherein the colored self-cleaning aluminum sheet product realizes a uniformity rating of at least about D.

15. The method of claim 1, wherein the colored self-cleaning aluminum sheet product realizes a uniformity rating of at least about B.

16. The method of claim 1, wherein the colored self-cleaning aluminum sheet product realizes a uniformity rating of at least about A.

17. The method of claim 1, wherein the colored self-cleaning aluminum sheet product is iridescent-free.

18. The method of claim 1, wherein the barrier layer has a thickness of not greater than about 1 micron.

19. The method of claim 1, wherein the self-cleaning layer has a thickness of not greater than about 1 micron.

20. The method of claim 1, wherein the self-cleaning layer achieves a water contact angle of not greater than about 25°

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