Encapsulated panel assemblies and methods for making same

• US 7,939,161 B2
• Filed: 12/18/2007
• Issued: 05/10/2011
• Est. Priority Date: 12/19/2006
• Status: Active Grant

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Pocock, Marc A., Allam, Dominic Joseph
• Primary Examiner(s): Shosho; Callie E
• Assistant Examiner(s): Khatri; Prashant J
• Application Number:
  US11/958,983
• Publication Number:
  US 20080213545A1
• Time in Patent Office: 1,239 Days
• Field of Search: 264/233, 264/328.1, 216/65, 524/730, 524/731, 524860-863, 522/99, 525100-107, 525/44, 528/26, 427/284
• US Class Current: 428/192
• CPC Class Codes: B29C 45/14311 using means for bonding the coating to the articles B29C45/14795 takes precedence
• CPC Class Codes: B29C 45/14434 Coating brittle material, e.g. glass B29C45/14377, B29C45/14418 take precedence
• CPC Class Codes: B29L 2031/30 Vehicles, e.g. ships or aircraft, or body parts thereof vanes or blades B29L2031/08, air bags B29L2022/027
• CPC Class Codes: C08G 77/04 Polysiloxanes
• CPC Class Codes: C09D 4/06 Organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond in combination with a macromolecular compound other than an unsaturated polymer of groups C09D159/00 - C09D187/00
• CPC Class Codes: Y02P 20/582 Recycling of unreacted starting or intermediate materials
• CPC Class Codes: Y10T 428/24777 Edge feature

Abstract

A panel assembly, and method of making it, that includes a substrate and a coating proximate at least one edge of the substrate for defining a coated edge portion, the coating including one or more film forming resins having at least one functional group capable of polymerization; an initiator for causing the formation of free radicals or cations; and one or more compounds, which are reactive with the film forming resin and which also contain at least one acidic moiety. A plastic is bonded onto the coated edge portion of the substrate.

Claims

1. A panel assembly, comprising:

a) a substrate comprising a panel of glass, plastic or a combination thereof which is at least partially transparent;

b) a cured coating on at least one peripheral edge portion of the substrate for defining a coated edge portion, the coating including;

i) one or more film forming resins having at least one functional group capable of polymerization;

ii) an initiator for causing the formation of free radicals or cations; and

iii) one or more compounds, which are reactive with the film forming resin and which also contain at least one acidic moiety consisting of a carboxylic acid group and a double bond, selected from the group consisting of acrylate, methacrylate, vinyl and allyl group containing compounds; and

iv) one or more adhesion promoters comprising a Michael addition product of a compound containing three or greater alkoxysilyl groups and an amino group with a compound containing two or more acrylate groups, and

c) a plastic bonded onto the coated edge portion of the substrate, the assembly being free of any ceramic frit beneath the plastic, wherein the substrate is encapsulated by the plastic about the entire periphery of the substrate.

2. The panel assembly of claim 1, wherein the coating includes:

a) from about 10 to about 70 parts by weight of the one or more of the film forming resin;

b) from about 2 to about 30 parts by weight of one or more reactive diluents;

c) from about 1 to about 30 parts by weight of one or more of the adhesion promoter;

d) from about 1 to about 10 parts by weight of one or more of the compounds containing at least one acidic moiety; and

,

e) from about 2 to about 20 parts by weight of one or more of the initiators;

wherein the coating contains 100 parts.

3. The panel assembly of claim 2, wherein the coating is one cured upon exposure to ultraviolet light.

4. The panel assembly of claim 2, the assembly being substantially free of a separate primer.

5. The panel assembly of claim 1, wherein:

a) the substrate includes a peripheral edge portion that surrounds a generally transparent central portion,

b) the coating includes a film forming resin containing (meth)acrylate functionality and a photoinitiator; and

the plastic bonded to the coated edge portion of the substrate is selected from a polyurethane, a polyvinylchloride, a thermoplastic polyolefin, a polyolefin, or any combination thereof, and being molded onto the coated edge portion of the substrate, the assembly being free of a separate primer.

6. The assembly according to claim 1 wherein the substrate is a thin panel having generally opposing parallel outer surfaces that are flat, arcuate, or a combination of both.

7. The assembly according to claim 6 wherein the substrate comprises glass or abrasion resistant coated plastic.

8. The assembly according to claim 1 wherein the coating further comprises one or more fillers having a Mohs hardness of greater than about 7.

9. The assembly according to claim 1 wherein the adhesion promoter is a Michael Addition Product having six or greater alkoxysilane groups.

10. The assembly according to claim 1 wherein the adhesion promoter is a Michael Addition product comprising the reaction product of an amino silane and a polyacrylate.

11. A method of making a panel assembly, comprising the steps of:

a) applying a coating on at least one peripheral edge portion of a substrate, comprising a panel of glass, plastic or a combination thereof which is at least partially transparent, for defining a coated portion, the coating including;

i) one or more film forming resins having at least one functional group capable of polymerization;

ii) an initiator for causing the formation of free radicals or cations;

iii) one or more compounds, which are reactive with the film forming resin and which also contain at least one acidic moiety consisting of a carboxylic acid group and a double bond, selected from the group consisting of acrylate, methacrylate, vinyl and allyl group containing compounds; and

iv) one or more adhesion promoters comprising a Michael addition product of a compound containing three or greater alkoxysilyl groups and an amino group with a compound containing two or more acrylate groups,

b) curing the coating;

c) positioning the substrate in a fixture for exposing the at least one portion; and

d) securing a plastic onto the coated peripheral edge portion of the substrate, wherein the substrate is encapsulated by the plastic about the entire periphery of the substrate.

12. The method of claim 11, wherein the securing step includes reaction injection molding the plastic.

13. The method of claim 12, wherein the plastic secured to the coated peripheral edge of the substrate is a polyurethane.

14. The method of claim 13, wherein the plastic is initially contacted with the coating as precursor reactants in a liquid state.

15. The method of making a panel assembly of claim 11, wherein:

a) the applying step, the coating includes a film forming resin containing (meth)acrylate functionality;

b) the curing step is achieved by radiation;

c) in the positioning step, the substrate is at least partially in a mold assembly for exposing the at least one portion within a cavity of the mold assembly; and

d) the securing step is achieved by contacting the plastic in a liquid state with the coated portion of the substrate in the mold cavity; and

solidifying the plastic for at least partially covering the coated portion.

16. The method according to claim 11 wherein the coating further comprises one or more fillers having a Mohs hardness of greater than about 7.

17. The method according to claim 11 wherein the adhesion promoter is a Michael Addition product comprising the reaction product of an amino silane and a polyacrylate.