Metallic coating system

Abstract

Provided herein is a method of applying a metallic coating system, the method comprising the steps of: 1) applying at least one basecoat to at least one substrate; and 2) coating the basecoat with at least one metallic basecoat layer. The at least one metallic basecoat layer can comprise at least one metallic pigment in an acrylic dispersion, wherein the at least one metallic pigment is a PVD pigment. Also described is an article comprising the metallic coating system coating disclosed herein.

Description

Technical Field

[0001] This disclosure relates entirely to a method of applying a metallic coating system, the method comprising the steps of: 1) applying at least one primer to at least one substrate; and 2) coating the primer with at least one metallic base coat. The at least one water-based metallic base coat may comprise at least one metallic pigment in an acrylic dispersion, wherein the at least one metallic pigment is a PVD pigment. The at least one solvent-based metallic base coat may comprise at least one metallic pigment in an acrylic resin solution, wherein the at least one metallic pigment is a PVD pigment. An article comprising a coating of the metallic coating system disclosed herein is also described. Background Technology

[0002] Metallic coatings have long been a popular choice for automobiles, motorcycles, bicycles, and other vehicles. These coatings are also used in other applications such as wheel rims, eyeglasses, watches, mobile phones, electronics, household appliances, and automotive interiors, as well as car accessories such as door handles. Typical metallic coating systems are usually applied in multiple layers, including a primer layer, a metallic base coat layer, and a clear coat. These conventional metallic coating systems may also include additional layers, such as a base coat and a leveling coat.

[0003] Specifically, silver metallic colors are increasingly popular for metallic coatings. Customers expect attributes such as brightness, lightness, hiding power, and strong angle-dependent anisotropy (as measured by the angle-dependent anisotropy index, which is a measure of the change in lightness of a metallic color as it is tilted across the entire viewing angle range; metallic coatings offer a high angle-dependent anisotropy index and are described in the "Test Results" section), or a duotone effect (applied angle-dependent lightness) combined with perfect non-floating behavior (essentially mirror-like). While conventional metallic pigments such as coin or cornflake types impart shimmer, these conventional metallic pigments do not provide depth and a mirror-like appearance. Innovations in aluminum flake pigment development have made it possible to achieve a unique metallic look with high brightness and a chromium effect using very thin metallic pigments known as PVD (Physical Vapor Deposition) or VMF (Vacuum Metallization Flake) pigments. Due to the lower layer thickness of PVD pigments, these PVD pigments can lie flat on the substrate and reflect light, so the color appears brighter / darker when viewed from different angles, and the color imparts low shimmer. Recently, PVD (Physical Vapor Deposition) aluminum pigments have attracted attention as a preferred silver finish for automotive exterior coatings. Generally, aluminum pigments currently produced through ball milling have high particle size and thickness, thus reducing brightness and reflectivity. However, specialized manufacturing methods can produce aluminum pigment particles with a size of approximately 10µm to 12µm and extremely small thickness (30nm to 50nm). The combination of these two characteristics (smaller particle size and thickness) can impart a specific mirror-like or chrome-like effect with high brightness and excellent image reflection, which is highly desirable in premium automotive topcoats.

[0004] While the mirror-like appearance depends on the structure of the PVD pigment particles, the smoothness of the underlying substrate also plays a role. Specifically, the high mobility and small particle size of metallic pigments (including PVD metallic pigments) make the substrate smoothness crucial. Rough surfaces can create localized defects on thin aluminum layers, which eventually become visible on the substrate. For example, these visual defects can produce an undesirable "orange peel" effect. Therefore, ensuring a smooth and defect-free substrate before applying the coating is essential.

[0005] However, currently available application methods for coatings containing PVD or VMF pigments in metallic finishes are time-consuming and complex. Proper application methods and layer construction are crucial to achieving the desired appearance of metallic coatings containing PVD or VMF pigments. Since PVD and VMF pigments are oriented according to the substrate, the substrate surface must be smooth and free of defects. Therefore, for automotive coatings, the substrate must be sanded using very fine grit. In some cases, applying a leveling binder or clear coat is also recommended. Furthermore, the metallic base coat containing PVD or VMF pigments should be applied in multiple thin layers.

[0006] Furthermore, achieving high angle-dependent colorimetric index and low grain size values ​​remains challenging in metallic coatings, especially in repair coating applications. Given these challenges in conventional metallic coatings, including those incorporating PVD or VMF pigments, there is still a need for coatings utilizing improved application processes that are faster and simpler than currently available solutions on the market. Attached Figure Description

[0007] Preferred embodiments of the invention will be described in detail in the specification and illustrated in the accompanying drawings, which form a part of the specification, wherein:

[0008] Figure 1 A conventional metal coating system is illustrated.

[0009] Figure 2 An option for a conventional metal coating system with PVD metallic pigments is illustrated.

[0010] Figure 3 A second option for conventional metal coating systems with PVD metallic pigments is illustrated.

[0011] Figure 4 The metal coating system claimed and described herein is illustrated.

[0012] Figure 5 Exemplary applications of the methods described herein are illustrated. Summary of the Invention

[0013] The embodiments described herein are not intended to be exhaustive or limiting of what is provided in the claimed subject matter and disclosed in the detailed description. Rather, the embodiments were chosen and described so that others skilled in the art can recognize and understand the principles and practices provided in the claimed subject matter.

[0014] A method for applying a metallic coating system includes the steps of: 1) applying at least one primer to at least one substrate; and 2) coating the primer with at least one metallic base coat. The at least one primer must have a specific color, as its hue and tint may have a major influence on the appearance of the base coat. The at least one primer may contain a colored dispersion, and the colored dispersion may contain at least one acrylic substance. Furthermore, the at least one primer may be mixed with at least one thinner before application. After the primer dries, the metallic base coat (i.e., a PVD metallic base coat) is applied in layers of a certain thickness, and flash-dried between each application. The thickness of each layer of the PVD metallic base coat is typically in the range of about 6 micrometers to 8 micrometers (the total base coat thickness is about 30 micrometers to 40 micrometers after multiple coats have been applied), while the thickness of a tint typically used in metallic coating systems is about 10 micrometers to 12 micrometers. In one embodiment, at least one aqueous metallic base coat may contain at least one metallic pigment in an acrylic dispersion, and the at least one metallic pigment is a PVD pigment. In another embodiment, at least one solvent-based metallic base coat may comprise at least one metallic pigment in an acrylic resin solution, wherein the at least one metallic pigment is a PVD pigment. After applying the PVD base coat, at least one top coat may be applied. The thickness of the top coat is typically in the range of about 6 to 8 micrometers. Subsequently, at least one clear coat may be applied to the top coat. The total clear coat may be in the range of about 50 to 80 micrometers, wherein the total clear coat is applied in more than one layer, and each layer has a thickness of about 25 to 40 micrometers. The method may also include applying at least one droplet at an angle / diagonal to substantially bisect at least one metallic base coat.

[0015] It also describes an article comprising a coating of the metal coating system disclosed herein.

[0016] To achieve the foregoing and related objectives, the following description illustrates certain exemplary aspects and specific embodiments. These exemplary aspects and specific embodiments indicate only some of a number of ways in which one or more aspects may be adopted. Other aspects, advantages, and novel features of this disclosure will become apparent upon consideration from the following detailed description. Detailed Implementation

[0017] Aspects of the content described herein are disclosed in the following description relating to specific implementations. Alternative implementations may be designed without departing from the scope of the content described herein. Furthermore, well-known implementations of the content described herein may be omitted or not described in detail so as not to obscure the relevant details of the content described herein. Further, for ease of understanding this specification, several terms used herein are discussed below.

[0018] As used herein, the term "exemplary" means "serving as an example, instance, or illustration." The embodiments described herein are not restrictive but merely exemplary. It should be understood that the described embodiments are not necessarily to be construed as preferred or advantageous over other embodiments. Furthermore, the term "implementation" does not require all embodiments to include the features, advantages, or modes of operation discussed.

[0019] This disclosure relates in its entirety to coating systems that offer advantageous improvements over current coatings, particularly metallic coatings. It has been found that a method for applying a metallic coating system (comprising the steps of: 1) applying at least one primer to at least one substrate; and 2) coating the primer with at least one metallic base coat) can surprisingly produce improved visual appearance compared to other metallic coatings, particularly in terms of angular heterochromaticity index, color and graininess matching a reference color, and other advantages.

[0020] In many embodiments, a method for applying a metallic coating system includes the steps of: 1) applying at least one primer to at least one substrate; and 2) coating the primer with at least one metallic base coat. While currently available solutions require multilayer systems with at least six different coatings and typically require the addition of components such as hardeners, the method described herein requires only a maximum of four coatings. Therefore, the entire process becomes faster and simpler using the described application method. Furthermore, the method described herein can be used during original equipment manufacturing (OEM) or in aftermarket applications such as touch-up painting or crash repair, providing a more efficient application method. Figure 4 and Figure 5 The diagram provides graphical details for the methods used for application.

[0021] In many embodiments, the method described herein can utilize spray application technology. In one embodiment, the method described herein can utilize an HVLP (High Flow Low Pressure) spray gun or a similar application device. Other application methods are also contemplated.

[0022] In many embodiments, at least one substrate is included, wherein the substrate comprises wood, metal, glass, plastic, paper, leather, fabric, ceramic, concrete, cement, or any combination thereof. Other substrates are also contemplated.

[0023] In many embodiments, at least one primer layer may comprise a colored dispersion, and the colored dispersion may comprise at least one acrylic substance. In other embodiments, the acrylic substance may be an acrylic emulsion. In many embodiments, at least one acrylic substance has a glass transition temperature (Tg) of about -10°C to about 40°C. The Tg described herein was measured using differential scanning calorimetry (DSC) according to ASTM D6604-00.

[0024] In some embodiments, the acrylic compounds can be formed from alkyl (meth)acrylates and vinyl monomers, such as, but not limited to, methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, n- / iso / tert-butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, lauryl (meth)acrylate, stearyl (meth)acrylate, hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate, hydroxybutyl (meth)acrylate, glycidyl methacrylate, 4-hydroxybutyl acrylate glycidyl ether, 2-(acetylacetoxy)ethyl methacrylate, lauryl methacrylate, stearyl methacrylate, cyclohexyl methacrylate, diacetone acrylamide, acrylamide, methacrylamide, hydroxymethyl (meth)acrylamide, styrene, α-methylstyrene, vinyltoluene, vinyl acetate, vinyl propionate, allyl methacrylate, or combinations thereof. In some embodiments, the alkyl methacrylate polymers can be those prepared from C12 to C22 alkyl methacrylates. Some preferred monomers include styrene, methyl methacrylate, methacrylic acid, hydroxyethyl acrylate, acetyl methacrylate, butyl acrylate, butyl methacrylate, or combinations thereof. Others are also contemplated.

[0025] In some embodiments, the acrylic material can be modified using another technique, such as silicone, epoxy, polyurethane, and combinations thereof. In many embodiments, the acrylic material can constitute 25% to 70% by weight of the primer. In other embodiments, the acrylic material can be, for example, in the following proportions: about 25% to about 65%, about 25% to about 60%, about 25% to about 55%, about 25% to about 50%, about 25% to about 45%, about 25% to about 40%, about 25% to about 35%, about 30% to about 70%, about 30% to about 65%, about 30% to about 60%, about 30% to about 55%, about 30% to about 50%, about 30% to about 45%, about 30% to about 40%, about 30% to about 35%, about 35% to about 70%, about 35% to about 65%, about 35% to about 60%, about 35% to about 55%, about 35% to about 5 ...60%, about 35% to about 60%, The range is approximately 45%, approximately 35% to approximately 40%, approximately 40% to approximately 70%, approximately 40% to approximately 65%, approximately 40% to approximately 60%, approximately 40% to approximately 55%, approximately 40% to approximately 50%, approximately 40% to approximately 45%, approximately 45% to approximately 70%, approximately 45% to approximately 65%, approximately 45% to approximately 60%, approximately 45% to approximately 55%, approximately 45% to approximately 50%, approximately 50% to approximately 70%, approximately 50% to approximately 65%, approximately 50% to approximately 60%, approximately 50% to approximately 55%, approximately 55% to approximately 70%, approximately 55% to approximately 65%, approximately 55% to approximately 60%, approximately 60% to approximately 70%, and approximately 60% to approximately 65%. Other ranges are also contemplated. In many embodiments, the colored dispersion further comprises at least one pigment. In some embodiments, the pigment may comprise organic pigments, inorganic pigments, or combinations thereof. In one embodiment, at least one pigment may comprise a special effects pigment, such as a pearlescent pigment, a glass pigment, a metallic pigment, or a combination thereof. In some embodiments, at least one pigment may include titanium dioxide, mica, various colored pigments, or combinations thereof.

[0026] In many embodiments, at least one primer layer may be mixed with at least one thinner before being applied to the substrate. In many embodiments, at least one primer layer is thinned by at least 10% before being applied to the substrate. In other embodiments, at least one primer layer is thinned by at least 20% before being applied to the substrate. In still other embodiments, at least one primer layer is thinned by at least 30% before being applied to the substrate. In another embodiment, at least one primer layer is thinned by at least 40% before being applied to the substrate. In yet another embodiment, at least one primer layer is thinned by at least 50% before being applied to the substrate. In several embodiments, at least one primer layer is mixed with at least one thinner at a ratio of 1:1 to 2:1 before being applied to the substrate. In one embodiment, at least one primer layer is mixed with at least one thinner at a ratio of 1:1. In one embodiment, at least one primer layer is mixed with at least one thinner at a ratio of 2:1. In many embodiments, the thinner comprises at least one ketone. At least one ketone may include methyl isobutyl ketone, methyl isopentyl ketone, methyl propyl ketone, methyl n-pentyl ketone (MAK), or combinations thereof. Other ketones are also contemplated. At least one primer layer can be thinned with any type of thinner (also known as a diluent). Thinners dilute the coating to improve flow and leveling properties and provide an improved appearance. Thinners can be polyurethane, solvents, epoxy resins, acrylics, polyesters, or combinations thereof. Other types of thinners are also contemplated.

[0027] Furthermore, the second step of the method described herein is to apply a base coat using at least one metallic base coat. In many embodiments, the at least one metallic base coat comprises at least one metallic pigment in an acrylic dispersion or acrylic resin solution. In many embodiments, the at least one acrylic dispersion or acrylic resin solution has a glass transition temperature (Tg) of about -10°C to about 40°C. The Tg described herein was measured using differential scanning calorimetry (DSC) according to ASTM D6604-00. In many embodiments, acrylic substances can, for example, have a Tg of about -10°C to about 35°C, a Tg of about -10°C to about 30°C, a Tg of about -10°C to about 25°C, a Tg of about -10°C to about 20°C, a Tg of about -10°C to about 15°C, a Tg of about 0°C to about 40°C, a Tg of about 0°C to about 35°C, a Tg of about 0°C to about 30°C, a Tg of about 0°C to about 25°C, a Tg of about 0°C to about 20°C, a Tg of about 0°C to about 15°C, a Tg of about 0°C to about 10°C, and a Tg of about 10°C to about 40°C. The Tg ranges are approximately 10°C to approximately 35°C, approximately 10°C to approximately 30°C, approximately 10°C to approximately 25°C, approximately 10°C to approximately 20°C, approximately 15°C to approximately 40°C, approximately 15°C to approximately 35°C, approximately 15°C to approximately 30°C, approximately 15°C to approximately 25°C, approximately 20°C to approximately 40°C, approximately 20°C to approximately 35°C, approximately 20°C to approximately 30°C, approximately 25°C to approximately 40°C, approximately 25°C to approximately 35°C, and approximately 30°C to approximately 40°C. Other Tg ranges are also envisioned.

[0028] In some embodiments, the acrylic compounds can be formed from alkyl (meth)acrylates and vinyl monomers, such as, but not limited to, methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, n- / iso / tert-butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, lauryl (meth)acrylate, stearyl (meth)acrylate, hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate, hydroxybutyl (meth)acrylate, glycidyl methacrylate, 4-hydroxybutyl acrylate glycidyl ether, 2-(acetylacetoxy)ethyl methacrylate, lauryl methacrylate, stearyl methacrylate, cyclohexyl methacrylate, diacetone acrylamide, acrylamide, methacrylamide, hydroxymethyl (meth)acrylamide, styrene, α-methylstyrene, vinyltoluene, vinyl acetate, vinyl propionate, allyl methacrylate, or combinations thereof. In some embodiments, the alkyl methacrylate polymers can be those prepared from C12 to C22 alkyl methacrylates. Some preferred monomers include styrene, methyl methacrylate, methacrylic acid, hydroxyethyl acrylate, acetyl methacrylate, butyl acrylate, butyl methacrylate, or combinations thereof. Others are also contemplated.

[0029] In some implementations, acrylic materials can be modified using another technique, such as silicone, epoxy, polyurethane, and combinations thereof.

[0030] In many embodiments, the acrylic material may constitute 30% to 70% by weight of the base coating. In other embodiments, the acrylic material may be, for example, in the following proportions: about 25% to about 65%, about 25% to about 60%, about 25% to about 55%, about 25% to about 50%, about 25% to about 45%, about 25% to about 40%, about 25% to about 35%, about 30% to about 70%, about 30% to about 65%, about 30% to about 60%, about 30% to about 55%, about 30% to about 50%, about 30% to about 45%, about 30% to about 40%, about 30% to about 35%, about 35% to about 70%, about 35% to about 65%, about 35% to about 60%, about 35% to about 55%, about 35% to about 5 ... The range is approximately 45%, approximately 35% to approximately 40%, approximately 40% to approximately 70%, approximately 40% to approximately 65%, approximately 40% to approximately 60%, approximately 40% to approximately 55%, approximately 40% to approximately 50%, approximately 40% to approximately 45%, approximately 45% to approximately 70%, approximately 45% to approximately 65%, approximately 45% to approximately 60%, approximately 45% to approximately 55%, approximately 45% to approximately 50%, approximately 50% to approximately 70%, approximately 50% to approximately 65%, approximately 50% to approximately 60%, approximately 50% to approximately 55%, approximately 55% to approximately 70%, approximately 55% to approximately 65%, approximately 55% to approximately 60%, approximately 60% to approximately 70%, and approximately 60% to approximately 65%. Other ranges are also envisioned.

[0031] In some embodiments, at least one metallic pigment is a PVD pigment. In another embodiment, at least one metallic pigment is a VMF pigment. In one embodiment, the metallic pigment is aluminum, zirconium, titanium, stainless steel, copper, or a combination thereof. In one embodiment, the PVD pigment is aluminum, zirconium, titanium, stainless steel, copper, or a combination thereof. In many embodiments, at least one metallic pigment may be mixed with an organic color pigment. In many embodiments, the PVD pigment particles are shaped into flat flakes with a relatively high surface area and minor edge irregularities. Unbound by theory, the high mobility and non-floating properties of PVD pigments can provide the ability to be positioned in the dried coating, allowing the PVD pigments to overlap and be oriented parallel to the underlying substrate. Since the metallic effect is generally described as the ratio between reflected and scattered light, these flat and regular particles will enhance unidirectional light reflection and suppress multidirectional light scattering. Thus, with the increase in gloss in these coatings containing PVD pigments, a sharper image is reflected.

[0032] In many embodiments, at least one metallic base coat layer may be mixed with at least one thinner before applying the base coat. In many embodiments, at least one metallic base coat layer is thinned by at least 10% before applying the base coat. In some embodiments, at least one metallic base coat layer is thinned by at least 20% before applying the base coat. In another embodiment, at least one metallic base coat layer is thinned by at least 30% before applying the base coat. In yet another embodiment, at least one metallic base coat layer is thinned by at least 40% before applying the base coat. In one embodiment, at least one metallic base coat layer is mixed with at least one thinner at a 2:1 ratio. In one embodiment, at least one metallic base coat layer is mixed with at least one thinner at a 3:2 ratio. In one embodiment, at least one metallic base coat layer is mixed with at least one thinner at a 2:1 ratio. In one embodiment, at least one metallic base coat layer is mixed with at least one thinner at a 3:1 ratio. In one embodiment, at least one metallic base coat layer is mixed with at least one thinner at a 4:1 ratio. Other ratios are also contemplated. At least one metallic base coat can be thinned by any type of thinner (also known as a diluent). The thinner dilutes the coating to improve flow and leveling properties and provide an improved appearance. In many embodiments, the thinner comprises at least one ketone. The at least one ketone may include methyl isobutyl ketone, methyl isopentyl ketone, methyl propyl ketone, methyl n-pentyl ketone (MAK), or combinations thereof. Other ketones are also contemplated. The thinner may be a polyurethane, solvent, epoxy resin, acrylic substance, polyester, or a combination thereof. Other types of thinners are also contemplated.

[0033] In many embodiments, the first layer of the metallic base coat has a dry film thickness of less than 2 µm. In some embodiments, the first layer of the metallic base coat has a dry film thickness of less than 1 µm.

[0034] In many embodiments, the second layer of the metallic base coat is applied substantially perpendicular to the first layer of the metallic base coat. In many embodiments, the second layer of the metallic base coat has a dry film thickness of less than 5 µm. In other embodiments, the second layer of the metallic base coat has a dry film thickness of less than 3 µm.

[0035] In many embodiments, the third layer of the metallic base coat is applied substantially perpendicular to the second layer of the metallic base coat. In many embodiments, the third layer of the metallic base coat has a dry film thickness of less than 5 µm. In some embodiments, the third layer of the metallic base coat has a dry film thickness of less than 3 µm.

[0036] In many embodiments, the fourth layer of the metallic base coat is applied substantially perpendicular to the third layer of the metallic base coat. In some embodiments, the fourth layer of the metallic base coat has a dry film thickness of less than 2 µm. In one embodiment, the fourth layer of the metallic base coat has a dry film thickness of less than 1 µm.

[0037] In one embodiment, the method of applying the metallic coating system further includes applying at least one drop layer at an angle / diagonal to substantially bisect any one of the following: a first layer of metallic base coat, a second layer of metallic base coat, a third layer of metallic base coat, a fourth layer of metallic base coat, or a combination thereof. In some embodiments, the drop layer has a dry film thickness of less than 5 µm. In other embodiments, the drop layer has a dry film thickness of less than 3 µm.

[0038] In several embodiments, the method of applying the metallic coating system further includes applying at least one drop layer at an angle / diagonal to substantially bisect at least one metallic base coat. In many embodiments, the at least one drop layer has the same or substantially similar composition to the PVD metallic base coat. In some embodiments, the drop layer has a dry film thickness of less than 5 µm. In other embodiments, the drop layer has a dry film thickness of less than 3 µm.

[0039] In many embodiments, the method of applying a metallic coating system further includes applying at least one primer to the substrate before applying at least one base coat.

[0040] In many embodiments, the method of applying a metallic coating system further includes applying at least one varnish coating to at least one metallic base coat, at least one drop coat, or a combination thereof.

[0041] In some embodiments, the metal coating system described herein is water-based. In other embodiments, the metal coating system described herein is solvent-based. In still other embodiments, the metal coating system described herein may be a combination of water-based and solvent-based coatings.

[0042] This document also describes an article comprising: 1) a substrate having at least one main surface; and 2) a metallic coating system prepared by the method described herein, wherein the metallic coating system is at least partially coated onto the substrate, wherein the substrate comprises wood, metal, glass, plastic, paper, leather, fabric, ceramic, or any combination thereof. The method of applying the metallic coating system comprises the steps of: 1) applying at least one primer to at least one substrate; and 2) coating the primer with at least one metallic base coat. At least one water-based metallic base coat may contain at least one metallic pigment in an acrylic dispersion, wherein the at least one metallic pigment is a PVD pigment. At least one solvent-based metallic base coat may contain at least one metallic pigment in an acrylic resin solution, wherein the at least one metallic pigment is a PVD pigment.

[0043] Figure 1 A conventional metal coating system 100 is illustrated. For the application of the illustrated conventional metal coating system 100, the coating is typically applied by HVLP spraying. Figure 1 All coatings in the coating system described herein can be cured for 30 to 60 minutes at room temperature (20°C to 25°C) or elevated temperatures (e.g., 60°C), depending on the formulation designed for the coating within the conventional metallic coating system 100. Primer 110 is optional, depending on the type of repair. After primer 110 has dried sufficiently, if the primer is a sanding primer, it must be sanded, for example, using a P400-P500 sanding step. If primer 110 is a non-sanding primer, sanding is not required. More than one layer of primer 110 may be present. Next, an optional base coat 120 may be applied. Base coat 120 should be a base coat with a certain desired color. Like primer 110, base coat 120 should be dried before proceeding to the next step. More than one base coat 120 may be present. For the next step, a metallic base coat 130 containing a conventional metallic tint is applied. The metallic base coat can contain conventional metallic pigments, such as cornflake aluminum pigment and silver coin aluminum pigment. The metallic base coat 130 can be diluted with 10% thinner and applied in at least two wet coats for coverage. Drying between the two wet coats is optional. After the metallic base coat 130 has dried, a drop coat (not shown) similar to or the same as the metallic base coat 130 can be applied at a lower pressure but with a similar dry film thickness. Drop coats can provide better blending, especially in the case of metallic paints such as silver and gold, which are prone to halo effects at edges by reducing or eliminating dry edges. Finally, after the metallic base coat 130 has dried sufficiently, at least one clear coat 140 can be applied. At least one clear coat 140 can provide a glossy appearance and improved durability.

[0044] In some cases, with Figure 1 The same method described for conventional metal coating system 100 can be used for metallic base coats containing PVD metallic pigments instead of conventional metallic pigments.

[0045] Figure 1 The conventional method described requires at least five coatings and is time-consuming to apply. Therefore, there is a need for systems with fewer coatings and systems that take less time to apply.

[0046] Figure 2 An example is provided for a conventional metal coating system with PVD metallic pigments. (For...) Figure 1 The application methods for conventional metallic coating systems and PVD metallic coating systems (as shown) are generally different. More steps and more layers are required to achieve the desired appearance of the PVD metallic base coat. Therefore, compared to... Figure 1 Compared to conventional metal coating systems described herein, currently available methods for PVD metal coating systems are time-consuming and complex.

[0047] Figure 2 An example of a first conventional PVD metallic coating system 200 is provided. First, [the following is a description of the process]. Figure 2 A primer 210 is applied to the substrate and dried. The primer 210 is then typically sanded. For example, a P600-P800-P1000 sanding step can be used to sand the primer 210. Subsequently, a layer of leveling adhesive 220 is applied and dried. The leveling adhesive 220 is used to provide a uniform surface (especially after sanding the primer 210) and to remove any sanding scratches. After the leveling adhesive 220 has dried, at least one base coat 230 can be applied, but this step is optional. The base coat 230 is typically a base coat with certain pigments and can be substantially similar to or identical to the PVD metallic base coat 240. After the base coat 230 has dried, a PVD metallic base coat 240 containing PVD metallic pigments can be applied. In some embodiments, the PVD metallic base coat 240 can be diluted with 10% to 50% thinner. First, apply approximately 25% of the PVD metallic base coat 240 and allow it to dry. Then, typically in a cross-coat manner, apply five additional coats of the PVD metallic base coat 240, each covering approximately 75% of the surface. Between each coat, the PVD metallic base coat 240 should be dried, thus increasing both process time and labor. A final coat of the PVD metallic base coat 240, covering approximately 25% of the surface, is then applied and allowed to dry at room temperature for 20 to 30 minutes. Finally, at least one clear coat 250 may be applied first, partially or partially, over a partially or partially closed coating, allowed to dry for 3 to 5 minutes, and then completely coated with the clear coat 250.

[0048] Figure 3 A second option is illustrated for conventional metal coating systems with PVD metallic pigments. Figure 2 The application method shown is the same, used for ( Figure 1 The application methods for conventional metallic coating systems and PVD metallic coating systems (as shown) are typically different. Achieving the desired appearance of the PVD metallic base coat requires more steps and layers, making the application method time-consuming and complex.

[0049] First, apply Figure 3 A primer 310 is applied and dried. The primer 310 may be sanded. For example, the primer 310 may be sanded using a sanding step of P600-P800. Subsequently, at least one partial layer and at least one complete layer (second layer) of a clear coat 320 are applied onto the primer 310. The clear coat 320 is typically dried at an elevated temperature for 30 minutes, or allowed to dry overnight at room temperature. Next, the clear coat 320 may be sanded. For example, the clear coat 320 may be sanded using a sanding step of P1500-P3000 on areas where color will be applied, while areas where no color will be applied should be sanded using a final sanding step of at least P1500 or finer. Subsequently, at least one partial layer and at least one complete layer of a leveling adhesive 330 are applied and dried. Typically, the PVD metallic base coat 340 can be diluted with 10% to 50% thinner, and it is usually applied in 2 to 3 coats on top of the clear coat 320, with drying between all coats. Subsequently, at least one full coat of the (undiluted) PVD metallic base coat 340 can be applied on top of the diluted coat. This top layer of the PVD metallic base coat 340 should be dried, after which at least one clear coat 350 can be applied. Both partial and full coats of the clear coat 350 can be applied, with drying between layers.

[0050] Figure 4 The metallic coating system claimed and described herein is illustrated. Depending on the type of repair, primer 410 may be applied to the substrate. Figure 4The primer 410 is optional. If a primer 410 is required, its color may be substantially similar to or the same as the base coat 420, or it may be different from the base coat 420. The base coat 420 can be used to improve the hiding properties of the PVD metallic base coat 430 to be applied thereon. In many embodiments, the primer 410 may be sanded after drying and before applying the base coat 420. In some embodiments, the primer 410 may be sanded using P500, P600, and P800 sanding steps. Other sanding techniques are also contemplated.

[0051] In some embodiments, the primer 420 may be aqueous. In one embodiment, the primer 420 is a colored acrylic dispersion. In another embodiment, the primer 420 is a colored acrylic resin solution.

[0052] In another embodiment, the base coating 420 may be solvent-based.

[0053] In some embodiments, the primer 420 is mixed with a thinner before application. In one embodiment, at least one primer 420 is mixed with at least one thinner at a 1:1 ratio. In one embodiment, at least one primer 420 is mixed with at least one thinner at a 2:1 ratio. In many embodiments, at least one primer 420 is diluted by at least 10% before applying the substrate. In other embodiments, at least one primer 420 is diluted by at least 20% before applying the substrate. In still some embodiments, at least one primer 420 is diluted by at least 30% before applying the substrate. In another embodiment, at least one primer 420 is diluted by at least 40% before applying the substrate. In yet another embodiment, at least one primer 420 is diluted by at least 50% before applying the substrate. Other ratios for the primer 420 and the thinner are also contemplated.

[0054] In some embodiments, the base coat is black or a black hue. In other embodiments, the base coat is a gray hue. In most embodiments, the base coat is tinted to match the color of the substrate to be coated.

[0055] After the primer 410 has dried, it is typically sanded to ensure a smooth substrate. For example, a P500-P600-P800-P1000 sanding step can be used. Next, a base coat 420 can be applied. The base coat 420 should be a base color layer with some color. The color of the base coat 420 will generally influence the color of the final appearance. The base coat 420 can be diluted with a thinner and applied until it is covered. The base coat 420 can be diluted with a thinner in the range of 10% to 50%. The base coat 420 is then dried before proceeding to the next step. Next, a PVD metallic base coat 430 can be applied. In some embodiments, the PVD metallic base coat 430 can be diluted and applied. The PVD metallic base coat 430 can be diluted with a thinner in the range of 10% to 50%.

[0056] The method for applying PVD metallic base coat 430 is as follows: Figure 5 The process is described in further detail below. First, a mist coating (sometimes referred to as a “control layer”, and defined herein as a partial layer of the PVD metallic base coat 430 in which the coating is applied in a mist form rather than a full spray) should be applied and dried. Subsequently, two full coats (meaning a full spray) or two partial coats (meaning 50% to 90% of the PVD metallic base coat 430) should be applied and dried between the coats. In one embodiment, two 75% coats of the PVD metallic base coat 430 should be applied and dried between the coats. An optional partial coat of the PVD metallic base coat 430, ranging from 20% to 70%, may then be applied and dried. Finally, two drop coats (defined herein as PVD metallic base coat 430 applied at lower pressure, where the output ranges from 30% to 90%) should be applied and dried between the two drop coats. In some implementations, at least one additional droplet coating may be required to ensure uniform distribution of the effect pigment. Using this PVD metallic coating system 400 method, a simplified method for applying PVD metallic coatings can be obtained, thus providing advantages over conventional PVD metallic coatings.

[0057] exist Figure 4 In another version, a total of five layers of continuous PVD metallic base coat 430 are applied, each layer having a thickness of 6 to 8 micrometers. In this embodiment, the total thickness of the PVD base coat 430 is between 30 and 40 micrometers. For comparison, the thickness of a typical metallic coating can range from 10 to 12 micrometers.

[0058] Finally, at least one clear coat 440 may be applied on top of the PVD metallic base coat 430. The thickness of the clear coat 440 may be in the range of 50 micrometers to 80 micrometers. The clear coat 440 is typically applied in the following forms: 1) a partial haze layer and a full coat, or 2) two full coats, wherein the thickness of each coat is approximately 25 micrometers to 40 micrometers.

[0059] Figure 5 An exemplary application of the method described herein is illustrated, particularly for the application step of a metallic base coat. For step 1, a matte coating is applied in a specific direction. The matte coating has the same composition as the metallic base coat but is applied under similar pressure to the other layers, but has a lower dry film thickness. This reduced film thickness is achieved by spraying the article from a greater distance. After applying the matte coating, it is allowed to dry. Next, in step 2, a complete layer of the metallic base coat is applied in a direction substantially perpendicular to the matte coating in step 1. After applying the PVD metallic base coat, it is allowed to dry. For step 3, another complete layer of the PVD metallic base coat is applied in a direction substantially perpendicular to the metallic base coat in step 2. After applying the PVD metallic base coat, it is allowed to dry. For step 4, a portion of the previously applied PVD metallic base coat is applied in a direction substantially perpendicular to the metallic base coat in step 3. In this case, there is an application amount of 50% compared to the application amounts applied in steps 2 and 3. However, the partially applied PVD metallic base coat can be between 20% and 80% of the total amount applied in steps 2 and 3. After applying the diluted PVD metallic base coat, allow it to dry. Finally, in step 5, at least two drop coats are sprayed at an angle / diagonal to substantially divide at least one PVD metallic base coat. For the drop coats, the two drop coats can have a dry film thickness of less than 5 µm. An optional clear coat (not shown) can be applied to the dried PVD metallic base coat.

[0060] Test Results

[0061] Two tests were used to assess the appearance of the metallic coating: angle-dependent anisochromaticity index (ADI) and grain size. The differences in ADI and grain size are particularly noticeable when using PVD metallic coatings compared to conventional metallic coatings. ADI (also known as metallic effect) is the change in the reflected color of a metal as it rotates through different viewing angles. This ADI is also called metallic travel because the color should be bright at the point where light hits, and becomes darker when viewed from different angles. A surface with a high ADI will exhibit bright reflection when viewed from a (perpendicular) surface and dark reflection when viewed at an angle. Due to its excellent unidirectional reflection, PVD particles typically exhibit a higher ADI compared to conventional aluminum pigments. Grain size (also known as diffuse roughness) is a measure of the roughness of the final appearance. Grain size characterizes the visibility of particles under diffuse lighting. Grain size has been described as "the perception of surface inhomogeneity only when the surface is viewed under diffuse or partially diffuse lighting." Scintillation is related to the number of scintillation particles per unit area of ​​the coating and the intensity of these particles. Similarly, one definition of scintillation is: "the sensation of randomly distributed, unstable and highly luminous objects on a more extended and darker surface with uncorrelated lightness" (from Filip et al., J. Coat. Technology, Res. Vol. 18, pp. 1511-1530, (2021)).

[0062] These properties relate to the morphology, size, orientation, and concentration of pigment particles in the metallic coating: coarser, randomly oriented metallic particles (greater than 25µm) will give the surface a shimmering, bright yet sparkling appearance. On the other hand, smaller, well-oriented particles will produce a bright and highly reflective appearance while maintaining a glossy metallic finish. Unlike typical cornflake and coin pigments, which are stacked at different angles to create a highly shimmering and sparkling appearance, PVD metallic pigments are stacked at similar angles and are flat on the surface to provide a chrome-like appearance.

[0063] Compared to conventional metallic base coats, PVD metallic base coats should have a much higher angle-dependent colorimetric index and a lower grain size value. As provided in Table 1 below, the application methods described in the examples and figures above produce the following results regarding the angle-dependent colorimetric index and grain size.

[0064] Angle-dependent anisotropy is a measure of the change in lightness of a metallic color as it is tilted across the entire viewing angle. It can be described as the change in reflectance of a metallic coating over a measurement spanning a given viewing angle. An angle-dependent anisotropy of 0 indicates a pure color, while highly anisotropic metallic or pearlescent base coats / varnishes can have an angle-dependent anisotropy of 15 to 17. An angle-dependent anisotropy is typically measured using a multi-angle spectrophotometer, such as the BYK mac spectrophotometer. The test for the angle-dependent anisotropy is described in "Observation and Measurement of the Appearance of Metallic Materials - Part 1 - MacroAppearance," CS McCamy, Color Research and Application, Vol. 21, No. 4, August 1996, pp. 292-304. Specifically, the angle-dependent anisotropy is defined by the following formula:

[0065] Anisochromaticity index with respect to angle = (2.69 * (L) 15 -L 110 ) 1.11 ) / (L 45 ) 0·86 ,in:

[0066] L 15 The CIE L* value was measured at a reverse directional reflection angle of 15°.

[0067] L 45 The CIE L* value was measured at a retrograde reflection angle of 45°; and

[0068] L 110 The CIE L* value was measured at a retrograde reflection angle of 110°.

[0069] Grain size was measured using commercial instruments for measuring texture effects, such as the BYK-Mac-I. The BYK-Mac-I multi-angle spectrophotometer includes a CCD monochrome camera for measuring texture effects. Grain size was evaluated by taking images using the CCD camera under diffuse illumination conditions formed by a white-coated hemisphere. The images were then analyzed using a histogram of lightness levels, whereby the uniformity of bright and dark areas was summarized by a grain size value. A grain size value of zero indicates a pure color, while higher values ​​indicate that the sample will appear more grainy or coarser under diffuse light. Scintillation and grain size data provide information about flake size and concentration levels. Visually, silver finishes with coarser aluminum pigment appear more scintillated under direct illumination and more “grainy” under diffuse illumination.

[0070] Table 1: Test Results

[0071]

[0072] All the application methods listed in Table 1 were evaluated on a Mercedes Benz 0047 (Alubeam Silver) car. The results using the application method of this invention (Example 4) showed better matching to the OEM reference panel than other application methods (higher angular heterochromaticity index and lower graininess value), while providing a faster and simpler process compared to currently available solutions on the market.

[0073] Table 2: Additional test results using thinner

[0074]

[0075] The application methods shown in Table 2 were evaluated in both the Toyota 1L3 and Nissan KAB car colors, which respectively contain 98% and 91% PVD metallic base coats mixed with other colors. The results using the application method described herein (Example C) showed a better match to the OEM reference panel than other application methods, and also provided a higher angle-dependent color difference index and a lower graininess value. Example C utilizes the PVD metallic base coats described herein, wherein the ratio of the base coat to the thinner is 1:1. The thinner comprises a mixture of ketones, namely methyl isobutyl ketone and methyl isopentyl ketone. Furthermore, Example C provides a faster and simpler process compared to currently available solutions on the market.

[0076] Implementation Plan

[0077] The following implementation schemes are envisioned. All combinations of features and implementation schemes are envisioned.

[0078] Implementation Scheme 1: A method for applying a metallic coating system, the method comprising the steps of: 1) applying at least one base coat to at least one substrate; and 2) coating the base coat with at least one metallic base coat.

[0079] Implementation Scheme 2: According to the implementation scheme of Implementation Scheme 1, there is at least one substrate, wherein the substrate includes wood, metal, glass, plastic, paper, leather, fabric, ceramic or any combination thereof.

[0080] Implementation Scheme 3: According to any one of Implementation Schemes 1 to 2, at least one base coating layer comprises a colored dispersion, wherein the colored dispersion comprises at least one acrylic substance.

[0081] Implementation Scheme 4: According to any one of Implementation Schemes 1 to 3, wherein at least one primer layer is diluted by at least 10% before coating the substrate.

[0082] Implementation Scheme 5: According to any one of Implementation Schemes 1 to 3, wherein at least one primer layer is diluted by at least 20% before coating the substrate.

[0083] Implementation Scheme 6: According to any one of Implementation Schemes 1 to 5, wherein before coating the substrate, at least one primer is mixed with at least one thinner in a ratio ranging from 1:1 to 2:1.

[0084] Implementation Scheme 7: According to any one of Implementation Schemes 1 to 6, wherein at least one metallic base coat comprises at least one metallic pigment in an acrylic dispersion.

[0085] Implementation Scheme 8: According to the implementation scheme described in Implementation Scheme 7, at least one metallic pigment is a PVD pigment.

[0086] Implementation Scheme 9: According to any one of Implementation Schemes 1 to 8, wherein at least one metallic base coat is thinned by at least 10% before applying the base coat.

[0087] Implementation Scheme 10: According to any one of Implementation Schemes 1 to 8, wherein at least one metallic base coat is thinned by at least 20% before applying the base coat.

[0088] Implementation Scheme 11: According to any one of Implementation Schemes 1 to 10, the first layer of the metallic base coat has a dry film thickness of less than 2µm.

[0089] Implementation Scheme 12: According to the implementation scheme of Implementation Scheme 11, the second layer of the metallic base coat is applied substantially perpendicular to the first layer of the metallic base coat.

[0090] Implementation Scheme 13: According to the implementation scheme of Implementation Scheme 12, the second layer of the metallic base coat has a dry film thickness of less than 5µm.

[0091] Implementation Scheme 14: According to the implementation scheme of Implementation Scheme 12, the third layer of the metallic base coat is applied substantially perpendicular to the second layer of the metallic base coat.

[0092] Implementation Scheme 15: According to the implementation scheme of Implementation Scheme 14, the third layer of the metallic base coat has a dry film thickness of less than 5µm.

[0093] Implementation Scheme 16: According to the implementation scheme of Implementation Scheme 14, the fourth layer of the metallic base coat is applied substantially perpendicular to the third layer of the metallic base coat.

[0094] Implementation Scheme 17: According to the implementation scheme described in Implementation Scheme 16, the fourth layer of the metallic base coat has a dry film thickness of less than 2µm.

[0095] Implementation Scheme 18: According to any one of Implementation Schemes 16 to 17, the method further includes: applying at least one droplet coating at an angle / diagonal to substantially bisect any one of the following: the first layer of the metallic base coat, the second layer of the metallic base coat, the third layer of the metallic base coat, the fourth layer of the metallic base coat, or a combination thereof.

[0096] Implementation Scheme 19: According to any one of Implementation Schemes 1 to 17, the method further includes: applying at least one droplet coating at an angle / diagonal to substantially bisect at least one metallic base coat.

[0097] Implementation Scheme 20: According to any one of Implementation Schemes 18 to 19, wherein the droplet coating has a dry film thickness of less than 5 µm.

[0098] Implementation Scheme 21: According to any one of Implementation Schemes 1 to 20, the method further includes: applying at least one primer to the substrate before applying at least one base coat.

[0099] Implementation Scheme 22: According to any one of Implementation Schemes 1 to 21, the method further includes: applying at least one clear coat to at least one metallic base coat, at least one drop coat, or a combination thereof.

[0100] Implementation Scheme 23: An article comprising: 1) a substrate having at least one main surface; and 2) a metal coating system prepared by any one of Implementation Schemes 1 to 22, wherein the metal coating system is at least partially coated onto the substrate, wherein the substrate comprises wood, metal, glass, plastic, paper, leather, fabric, ceramic, or any combination thereof.

[0101] The foregoing description includes examples of the claimed subject matter. All details, as well as any modifications described in conjunction with the background and specific embodiments, will be apparent to those skilled in the art within the substance and scope of the claimed subject matter. Furthermore, it should be understood that aspects of the claimed subject matter, as well as portions of the various embodiments and features described below and / or in the appended claims, can be combined or interchanged, in whole or in part. In the foregoing description of the various embodiments, those embodiments referenced to another embodiment may be suitably combined with other embodiments, as will be recognized by those skilled in the art. Moreover, those skilled in the art will recognize that the foregoing description is presented as an example only and is not intended to limit the claimed subject matter, recognizing that many other combinations and arrangements of the claimed subject matter are possible. Of course, it is impossible to describe every conceivable combination of components or methods for the purpose of describing the claimed subject matter, but these will be recognized by those skilled in the art. Therefore, the claimed subject matter is intended to cover all such changes, modifications, and variations that fall within the substance and scope of the appended claims. Furthermore, with regard to the use of the term "comprising" in the specific embodiments or claims, such terms are intended to be inclusive in a manner similar to how the term "comprising" is interpreted as "comprising" when used as a transitional word in a claim.

Claims

1. A method for applying a metal coating system, the method comprising the following steps: Apply at least one base coat to at least one substrate; as well as The base coat is applied using at least one metallic base coat.

2. The method of claim 1, wherein at least one substrate comprises wood, metal, glass, plastic, paper, leather, fabric, ceramic, or any combination thereof.

3. The method according to any one of claims 1 to 2, wherein at least one base layer comprises a colored dispersion, wherein the colored dispersion comprises at least one acrylic substance.

4. The method according to any one of claims 1 to 3, wherein at least one primer layer is diluted by at least 10% before coating the substrate.

5. The method according to any one of claims 1 to 3, wherein at least one primer layer is diluted by at least 20% before coating the substrate.

6. The method according to any one of claims 1 to 5, wherein, prior to coating the substrate, at least one primer is mixed with at least one thinner at a ratio of 1:1 to 2:

1.

7. The method according to any one of claims 1 to 6, wherein at least one metallic base coat comprises at least one metallic pigment in an acrylic dispersion.

8. The method according to claim 7, wherein at least one metallic pigment is a PVD pigment.

9. The method according to any one of claims 1 to 8, wherein at least one metallic base coat is diluted by at least 10% before applying the base coat.

10. The method according to any one of claims 1 to 8, wherein at least one metallic base coat is diluted by at least 20% before applying the base coat.

11. The method according to any one of claims 1 to 10, wherein the first layer of the metallic base coat has a dry film thickness of less than 2 µm.

12. The method of claim 11, wherein the second layer of the metallic base coat is applied substantially perpendicular to the first layer of the metallic base coat.

13. The method of claim 12, wherein the second layer of the metallic base coat has a dry film thickness of less than 5 µm.

14. The method of claim 12, wherein the third layer of the metallic base coat is applied substantially perpendicular to the second layer of the metallic base coat.

15. The method of claim 14, wherein the third layer of the metallic base coat has a dry film thickness of less than 5 µm.

16. The method of claim 14, wherein the fourth layer of the metallic base coat is applied substantially perpendicular to the third layer of the metallic base coat.

17. The method of claim 16, wherein the fourth layer of the metallic base coat has a dry film thickness of less than 2 µm.

18. The method according to any one of claims 16 to 17, further comprising: At least one droplet is applied at an angle / diagonal to substantially bisect any of the following: the first layer of the metallic base coat, the second layer of the metallic base coat, the third layer of the metallic base coat, the fourth layer of the metallic base coat, or a combination thereof.

19. The method according to any one of claims 1 to 17, further comprising: Apply at least one drop of coating at a certain angle / diagonal to substantially bisect at least one metallic base coat.

20. The method according to any one of claims 18 to 19, wherein the droplet coating has a dry film thickness of less than 5 µm.

21. The method according to any one of claims 1 to 20, further comprising: Before applying at least one base coat, apply at least one primer to the substrate.

22. The method according to any one of claims 1 to 21, further comprising: Apply at least one clear coat to at least one metallic base coat, at least one drop coat, or a combination thereof.

23. An article of manufacture, said article comprising: A substrate having at least one main surface; and A metal coating system prepared by any one of claims 1 to 22, wherein the metal coating system is at least partially coated onto the substrate; The substrate may include wood, metal, glass, plastic, paper, leather, fabric, ceramic, or any combination thereof.

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