Resin molded articles

• US 9,121,090 B2
• Filed: 02/19/2009
• Issued: 09/01/2015
• Est. Priority Date: 02/20/2008
• Status: Active Grant

• Current Assignee: Daikyo Nishikawa Corporation, Hiroshima Prefecture
• Original Assignee: Daikyo Nishikawa Corporation, Hiroshima Prefecture
• Inventors: Suga, Takeharu, Okamura, Masaharu, Ahagon, Hiroshi, Kojima, Hiroharu, Nawachi, Norio, Yamamoto, Akira
• Primary Examiner(s): STACHEL, KENNETH J
• Application Number:
  US12/735,842
• Publication Number:
  US 20100327629A1
• Time in Patent Office: 2,385 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: C23C 16/0272 Deposition of sub-layers, e.g. to promote the adhesion of the main coating
• CPC Class Codes: C23C 16/30 Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
• CPC Class Codes: C23C 16/505 using radio frequency discharges
• CPC Class Codes: Y10T 428/265 1 mil or less

Abstract

In a resin molded article (M), a wear-resistant surface layer (2) is provided on a surface of a base (1) made of a thermoplastic resin with an undercoat layer (3) being interposed therebetween, and the surface layer (2) has a composition containing silicon, oxygen, carbon, and hydrogen, a thickness of 0.02 μm or greater and 0.48 μm or less, and a density of greater than 1.5 g/cm³ or a hardness of 1.5 GPa or greater.

Claims

1. A method for producing an automotive window glazing panel which includes a base made of a thermoplastic resin, a wear-resistant surface layer, and an undercoat layer interposed between the base and the wear-resistant surface layer so as to contact the base and the wear-resistant surface layer, comprising the steps of:

forming the undercoat layer over the base as an adhesive layer having a thickness of 7.5 μ

m or greater and 14.5 μ

m or less over the surface of the base, and

forming the wear-resistant surface layer over the undercoat layer as a plasma-enhanced CVD coating to a thickness of 0.04 μ

m or greater and 0.40 μ

m or less to reduce a Taber wear testing haze value of the glazing panel to between 2% and 0.70%, and a density of greater than 1.5 g/cm³ or a hardness of 1.5 GPa or greater with a composition consisting of silicon, oxygen, hydrogen and carbon,

wherein a composition ratio of the oxygen to the silicon in the wear-resistant surface layer is greater than or equal to 1.54 and less than 1.91, and a composition ratio of the carbon to the silicon is greater than or equal to 0.003 and less than 0.14.

2. An automotive window glazing panel comprising:

a base made of a thermoplastic resin; and

an undercoat layer and a wear-resistant surface layer provided on the base in this order,

wherein a thickness of the undercoat layer is greater than or equal to 7.5 μ

m and less than or equal to 14.5 μ

m,

a hardness of the undercoat layer is lower than that of the wear-resistant surface layer,

the hardness of the undercoat layer is greater than or equal to 100 MPa and less than or equal to 1.5 GPa,

the undercoat layer has a first undercoat layer made of a liquid acrylic resin material applied over the base and a second undercoat layer made of a liquid silicone resin material applied over the first undercoat layer,

the wear-resistant surface layer consists of silicon, oxygen, carbon, and hydrogen,

a composition ratio of the oxygen to the silicon in the surface layer is greater than or equal to 1.7 and less than 1.91, and a composition ratio of the carbon to the silicon is greater than or equal to 0.003 and less than 0.14,

a thickness of the wear-resistant surface layer is greater than or equal to 0.04 μ

m and less than or equal to 0.40 μ

m,

a density of the wear-resistant surface layer is greater than 1.5 g/cm³, and

a hardness of the wear-resistant surface layer is greater than or equal to 1.5 GPa,

wherein a Taber wear testing haze value of the glazing panel is between about 2% and 0.70%, and

wherein the wear-resistant surface layer is a plasma-enhanced CVD coating.