Method for production of an acrylic coated polycarbonate article

• US 5,271,968 A
• Filed: 02/20/1990
• Issued: 12/21/1993
• Est. Priority Date: 02/20/1990
• Status: Expired due to Term

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Coyle, Dennis J., Crouch, Earl T., Kerr, Stuart R. III, Katsamberis, Dimitris, Lewis, Larry N.
• Primary Examiner(s): Lusignan, Michael
• Application Number:
  US07/482,438
• Time in Patent Office: 1,400 Days
• Field of Search: 427/44, 427/54.1, 427/393.5, 427/558, 427/366, 428/412
• US Class Current: 427/558
• CPC Class Codes: B05D 2201/00 Polymeric substrate or laminate
• CPC Class Codes: B05D 2252/02 of indefinite length
• CPC Class Codes: B05D 3/067 Curing or cross-linking the coating
• CPC Class Codes: C08J 2369/00 Characterised by the use of polycarbonates; Derivatives of polycarbonates
• CPC Class Codes: C08J 2433/06 of esters containing only carbon, hydrogen, and oxygen, the oxygen atom being present only as part of the carboxyl radical
• CPC Class Codes: C08J 7/0427 with only one layer of a composition containing a polymer binder with more layers C08J7/042
• CPC Class Codes: C08J 7/043 Improving the adhesiveness of the coatings per se, e.g. forming primers adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50
• CPC Class Codes: C08J 7/046 Forming abrasion-resistant coatings; Forming surface-hardening coatings
• CPC Class Codes: Y10S 428/913 Material designed to be responsive to temperature, light, moisture
• CPC Class Codes: Y10T 428/24967 Absolute thicknesses specified
• CPC Class Codes: Y10T 428/259 Silicic material
• CPC Class Codes: Y10T 428/263 Coating layer not in excess of 5 mils thick or equivalent
• CPC Class Codes: Y10T 428/31 Surface property or characteristic of web, sheet or block
• CPC Class Codes: Y10T 428/31507 Of polycarbonate
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer

Abstract

A method for producing an abrasion-resistant, ultraviolet radiation cured coating on a surface of a polymeric substrate is disclosed, as well as the article produced from the method. The uncured coating material which is substantially free of non-reactive volatile components is (i) applied to the substrate (ii) heated along with the substrate to a temperature sufficient to drive a portion of the coating material into a region beneath the surface of the substrate, (iii) and cured onto the substrate by exposing the coating material under anaerobic conditions to sufficient ultraviolet radiation to cure the coating material. Heating of the solvent-free coating prior to ultraviolet radiation cure and while in contact with the substrate results in improved adhesion of the coating to the substrate.

Claims

1. A method for producing a polycarbonate article having an ultraviolet radiation cured surface coating, said method comprising the steps of:

a) contacting an ultraviolet radiation curable coating composition with a surface of a thermoplastic substrate for a period of time and at a temperature sufficient to allow a portion of said composition to diffuse into a region beneath said surface of said substrate to create a region comprising coating composition and thermoplastic resin, said temperature being between 90°

F. and 150°

F., said region having a thickness of from between 0.1 microns and 5 microns, said coating composition being substantially free of non-reactive volatile components; and

b) exposing said applied coating composition to sufficient ultraviolet radiation to effect cure of said coating composition.

2. The method of claim 1 wherein said cured coating composition consists of solids.

3. The method of claim 1, wherein said coating composition comprises a polyfunctional acrylate monomer, a photoinitiator and from 20 to 50 percent by weight of 1,6-hexanediol diacrylate.

4. The method of claim 1, wherein said temperature is from 110°

F. to 130°

F.

5. The method of claim 1, wherein said temperature is about 120°

F.

6. The method of claim 1, wherein said cured coating provides a hardcoat having a thickness of from 0.5 to 5 mil.

7. The method of claim 1 wherein said thermoplastic resin substrate is an aromatic polycarbonate resin substrate.

8. A method for providing an acrylic coated polycarbonate article, said method comprising the steps of:

a) applying an acrylic coating composition to a surface of an aromatic polycarbonate substrate, said coating composition comprising multifunctional acrylic monomers and a photoinitiator, said coating composition being substantially free of non-reactive volatile components;

b) heating said applied coating composition and said substrate having said coating composition thereon to a temperature of from 90°

F. to 150°

F. for a time sufficient to cause a portion of said coating composition to diffuse into a region of from 0.05 microns to 5 microns beneath said surface of the substrate; and

c) exposing said applied coating composition to sufficient ultraviolet radiation under substantially anaerobic conditions to effect cure of said coating composition.

9. A method for producing thermoplastic resin article having an ultraviolet radiation cured surface coating, said method comprising the steps of:

a) contacting an ultraviolet radiation curable coating composition with a surface of a thermoplastic substrate for a period of time and at a temperature sufficient to allow a portion of said composition to diffuse into a region beneath said surface of said substrate to create a region comprising coating composition and thermoplastic resin, said temperature being between 90°

F. and 150°

F., said region having a thickness of from between 0.1 microns and 5 microns; and

b) exposing said applied coating composition to sufficient ultraviolet radiation to effect cure of said coating composition.