Method of making painted automobile components

• US 5,693,710 A
• Filed: 04/28/1995
• Issued: 12/02/1997
• Est. Priority Date: 02/10/1993
• Status: Expired due to Term

• Current Assignee: Honda Giken Kogyo Kabushiki Kaisha (Honda Motor Company), Solvay Engineered Polymers, Inc. (Lyondellbasell Industries NV)
• Original Assignee: D & S Plastics International, Honda Giken Kogyo Kabushiki Kaisha (Honda Motor Company)
• Inventors: Wiseman, Mike, Kubota, Fumihiko, Katayanagi, Setsuo, Hermans, Jay, Chung, Dennis, Her, Jeff, Srinivasan, Sachit
• Primary Examiner(s): Warzel, Mark L.
• Application Number:
  US08/430,549
• Time in Patent Office: 949 Days
• Field of Search: 525/74, 525/240, 525/79, 525/63, 525/64, 525/69, 525/71, 427/407.1, 427/412.1, 427/412.3, 427/419.1
• US Class Current: 525/63
• CPC Class Codes: B05D 7/02 to macromolecular substances, e.g. rubber treatment or coating of shaped articles made of macromolecular substances C08J7/00
• CPC Class Codes: B05D 7/53 Base coat plus clear coat type
• CPC Class Codes: C08L 2205/03 containing three or more polymers in a blend
• CPC Class Codes: C08L 2205/035 containing four or more polymers in a blend
• CPC Class Codes: C08L 23/04 Homopolymers or copolymers of ethene
• CPC Class Codes: C08L 23/06 Polyethene
• CPC Class Codes: C08L 23/10 Homopolymers or copolymers of propene
• CPC Class Codes: C08L 23/12 Polypropene
• CPC Class Codes: C08L 23/14 Copolymers of propene C08L23/16 takes precedence
• CPC Class Codes: C08L 23/16 Elastomeric ethene-propene or ethene-propene-diene copolymers, e.g. EPR and EPDM rubbers
• CPC Class Codes: C08L 23/20 having four to nine carbon atoms
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/04 Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C08L 2666/24 Graft or block copolymers according to groups C08L51/00, C08L53/00 or C08L55/02; Derivatives thereof
• CPC Class Codes: C08L 51/06 grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
• CPC Class Codes: C08L 53/00 Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers

Abstract

A method of making articles of manufacture, such as automobile bumpers and other components, formed from thermoplastic olefin compositions, having improved resistance to gasoline and other fluids when painted with flexible coatings such as two component polyurethane paints, and the like, are disclosed. The compositions used to form these articles include a thermoplastic olefin such as crystalline polypropylene, crystalline polyethylene or mixtures thereof with a first rubber component of an ethylene propylene diene rubber having a high molecular weight and a second rubber component of an ethylene propylene diene rubber having a low molecular weight, wherein the first rubber component has a molecular weight of 4 to 200 times that of the second rubber component.

Claims

1. A method of making a painted article which comprises:

molding in the form of an article a polymer blend composition comprising about 40 to 90% by weight of the composition of a crystalline or semi-crystalline polyolefin, about 10% to 50% by weight of the composition of a first rubber component of an ethylene-propylene-diene rubber having a weight average molecular weight of about 40,000 to 300,000, and about 1 to 20% by weight of a second rubber component of an ethylene-propylene-diene rubber having a number average molecular weight of at least about 2,000, wherein the molecular weight of the first rubber component is at least about 4 to 200 times that of the second rubber component, and painting at least part of the article with a two-component polyurethane system comprising a base coat and a clear coat, wherein said base coat is selected from the group consisting of 2 component urethane metallic base coats and 2 component urethane solid base coats.

3. The method of claim 1 or 2 wherein the article is an automobile component.

4. The method of claim 3 wherein the automobile component is an automobile bumper.

5. The method of claim 1 which further comprises selecting the second rubber component to have a number average molecular weight of between about 2,000 and 10,000.

9. The method of claim 1 or 2 which further comprises selecting the olefin component to be semi-crystalline polyethylene, semi-crystalline polypropylene or mixtures thereof.

10. The method of claim 1 or 2 which further comprises adding to the polymer blend composition an agent for compatibilizing the olefin component with the first and second rubber components.

11. The method of claim 10 wherein the compatibilizing agent is a copolymer of polypropylene with a polar compound.

12. The method of claim 10 wherein the compatibilizing agent is a copolymer of polypropylene with at least one of either polystyrene, polyester, polyurethane, an acrylic compound, or a mixture thereof.

13. The method of claim 12 wherein the compatibilizing agent is a copolymer of polypropylene-graft-(styrene-co-hydroxypropylmethacrylate).

14. The method of claim 12 wherein the compatibilizing agent is a copolymer of polystyrene-co-acrylonitrile grafted with maleic anhydride.

15. The method of claims 1 or 2 which further comprises selecting the first rubber component to be ethylene-propylene-dicyclopentadiene and the second rubber component to be ethylene-propylene-ethylidene-norborene.

16. The method of claim 1 or 2 which further comprises selecting the first rubber component to be a mixture of a crystalline material and an amorphous material.

17. The method of claim 16 wherein the crystalline and amorphous materials are each present in an amount of about 35 to 65% by weight.

18. The method of claim 16 wherein the crystalline material comprises a mixture of at least about 60% ethylene and the balance propylene and wherein the amorphous material comprises a mixture of substantially equal amounts of ethylene and propylene.

19. The method of claim 18 wherein the crystalline material has a diene content of about 3 to 4% and the amorphous material has a diene content of about 5%.

20. The method of claim 16 wherein the crystalline and amorphous materials are present in substantially equal quantities.

2. A method of improving the fluid resistance of polymeric articles which comprises:

forming a polymer blend composition into a preform, said polymer blend composition comprising;

about 40 to 90% by weight of the composition of a crystalline or semi-crystalline polyolefin, about 10% to 50% by weight of the composition of a first rubber component of an ethylene-propylene-diene rubber having a weight average molecular weight of between about 40,000 and 300,000, and about 1 to 20% by weight of a second rubber component of an ethylene-propylene-diene rubber having a number average molecular weight of about 2,000 to 10,000; and

applying to one or more surfaces of said preform a paint composition comprising a base coat and a clear coat, wherein said base coat is selected from the group consisting of 2 component urethane metallic base coats and 2 component urethane solid base coats, wherein said paint composition durable adheres to said preform to improve the fluid resistance of the article.

6. The method of claim 2 or 5 which further comprises providing the first and second rubber components in sufficient amounts to obtain a weight ratio of between about 2:

1 and 10;

1, and wherein the number average molecular weight of the second rubber component is about 5,000 to 7,000.

7. The method of claim 6 wherein the second rubber component has a diene content of at least about 7%.

8. The method of claim 6 wherein the second rubber component has a diene content of at least about 10% and wherein the first and second rubber components are present in a weight ratio between about 3:

1 and 5;

1.