Davidson Textron Inc.

Ex-cell-o Gmbh

Textron Automotive Company Inc.

Richard C Eisfeller

John B Clark

Gerard L Vachon

Maureen M Lein

Alfred T Poliquin

Mark E Dukeshire

Richard W Finch

Ellen Lord

Stephen P McLaughlin

Robert D Sparling

Mark Burns

John T Russell

A process for manufacturing a metallized substrate using the island coating method, includes depositing a coating layer containing a radiation curable non-volatile film former. The coated part is then vacuum metallized to form the metal islands of the present invention. A layer of clear resinous protective dielectric topcoat containing a radiation curable non-volatile film former is then deposited to completely cover the layer of metal islands while maintaining the aesthetic properties of the metallizing island coating system at a reduced cost and with minimal variability among parts.

Radiation cured island coating system

A process for manufacturing a metallized part comprises the following steps. A part is provided made from a substrate material selected from the group consisting of thermoplastic urethane (TPU), TPU alloys, polyester alloys, nylon, thermoplastic olefins (TPO) and aluminum. A single protective layer (combined primer/basecoat) is spray deposited, flashed and cured over the substrate. Over the combined primer/basecoat layer, a layer of corrosion prone metal is vacuum deposited to form a discontinuous film covering the combined primer/basecoat layer. A layer of clear resinous protective dielectric topcoat is spray deposited and cured to completely cover the layer of vacuum deposited corrosion prone metal material and fill channels formed in the discontinuous film layer.

Combined primer/basecoat island coating system

An aluminum object is manufactured by a process including chromate conversion coating of the aluminum object; sequentially applying a primer coat to the outer surface and thereafter applying a dielectric substrate basecoat; vacuum metallizing a corrosion prone metal, namely indium, on the dielectric substrate basecoat to form 'islands' of the indium that are top coated with a clear resinous layer to encapsulate and insulate the islands, one from another. The indium islands are less than one thousand angstroms thick and have an average diameter of less than three thousand angstroms. The island structure is etched following the growth of the metal as it is deposited between the nucleation stage and the stage of channelization of formation of an electrically conductive film. The etchant is selected to clear channels between island structures to improve adhesion of a dielectric resinous top coat to the dielectric substrate by order of magnitude to adhesion to the islands.

System for making bright aluminum parts

A high gloss color finish for a plastic article is formed by coating and curing a colored primer layer (12) onto a plastic substrate (10). A light transmissive basecoat (14) is applied and cured onto the primer layer (12) to form a substrate (10) with a colored surface. Indium islands (20) are vacuum deposited onto the basecoat (12) to a thickness up to 100 Angstroms to form a visually macroscopically continuous layer (21). The island layer (21) is etched to remove smaller sized islands. A transparent topcoat (24) is applied onto the basecoat and indium islands and cured in place.

Method for producing high gloss bright colored plastic articles

A bright trim article is manufactured by a process including applying a primer coat material to the outer surface of a raw part and thereafter applying a dielectric substrate basecoat by rotation and spray painting to prevent orange peel; thereafter vacuum metallizing a corrosion prone metal, namely indium, on the dielectric substrate basecoat to form 'islands' of the indium that are etched following the growth of the metal as it is deposited after the nucleation stage and the stage of channelization but before the formation of an electrically conductive film; thereafter applying a clear resinous topcoat material by rotating the base-coated part and spraying the resinous topcoat material to prevent an orange peel surface while filling the channels and covering the islands to encapsulate and insulate the islands, one from another. A preferred application of this invention is the manufacture of trim parts for the automotive, plumbing and building industries.

Method for making bright trim articles

Vacuum metallizing substrates having both vertical and horizontal surfaces occurs by directing metal from two remote sources by thermal evaporation. One source is connected horizontally below the object to depose metal vertically toward the object to the horizontal surface thereof. The second source is connected vertically to the object to depose metal horizontally toward the object to the vertical surface thereof. A vacuum chamber contains a rotating carousel supporting the objects with the sources located fixedly within the chamber to perform the thermal evaporation.

Thermal evaporation in two planes

A plastic object is manufactured by a process including vacuum metallizing with a corrosion prone metal, namely indium, a dielectric substrate to form 'islands' of the indium top coated with a clear resinous layer which encapsulates and insulates the islands, one from another. The indium islands are less than one thousand angstroms thick and have an average diameter of less than three thousand angstroms. The island structure is etched following the growth of the metal as it is deposited between the nucleation stage and the stage of channelization of formation of an electrically conductive film. The etchant is selected to clear channels between island structures to improve adhesion of a dielectric resinous top coat to the dielectric substrate by order of magnitude to adhesion to the islands. A preferred application of this invention is the manufacture of exterior automobile trim components the base structure of which is a flexible elastomer such as a thermoplastic urethane.

Etching of vacuum metallized indium

A surprisingly corrosion and abuse resistant plastic object vacuum-metallized with a corrosion prone metal, namely indium, on a dielectric substrate consists of minute specular electrically-discrete 'islands' of the indium topcoated with a clear resinous layer which encapsulates and insulates the islands, one from another. The indium islands are less than one thousand angstroms thick and have an average diameter of less than three thousand angstroms. This island structure is secured by stopping the growth of the metal as it is deposited between the nucleation stage and the stage of channelization or formation of an electrically conductive film. The island structure permits the dielectric resinous topcoat to penetrate in, about and under the metal islands encapsulating and securely bonding them to the substrate. The vacuum deposited indium gives a bright sheeny appearance which, when properly topcoated, very closely duplicates the appearance of electrodeposited chrome. A preferred application of this invention is the manufacture of exterior automobile trim components the base structure of which is a flexible elastomer such as a thermoplastic urethane.

Vacuum metallizing a dielectric substrate with indium and products

A surprisingly corrosion and abuse resistant plastic object vacuum-metallized with a corrosion prone metal, on a dielectric substrate consists of minute specular electrically-discrete 'islands' of the metal topcoated with a clear resinous layer which encapsulates and insulates the islands, one from another. The metal islands are less than one thousand angstroms thick and have an average diameter of less than three thousand angstroms. This island structure is secured by stopping the growth of the metal as it is deposited between the nucleation stage and the stage of channelization or formation of an electrically conductive film. The island structure permits the dielectric resinous topcoat to penetrate in, about and under the metal islands encapsulating and securely bonding them to the substrate. A preferred application of this invention is the manufacture of exterior automobile trim components the base structure of which is a flexible elastomer such as a thermoplastic urethane and which have the appearance of electrodeposited chrome parts.

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Greenland, NH, United States of America

Richard C Eisfeller