Method of repairing paint film and articles comprising repaired paint film

Abstract

To provide a method of repairing a paint film.SOLUTION: A method of repairing a paint film comprises the steps of: removing damaged portions of a paint film from an underlying substrate to expose a damaged area; abrading the surface of the adjacent portion of the paint film adjacent the underlying substrate to which the paint film is no longer uniformly adhered; applying filler to the damaged area and to cover any exposed edges of the adjacent portion; abrading the outwardly exposed surface of the filler; applying primer to the outwardly exposed surface of the abraded filler and the adjacent portion; abrading the outwardly exposed surface of the primer; painting the outwardly exposed surface of the abraded primer and the adjacent portion; abrading the outwardly exposed surface of the paint; applying clear coat to the outwardly exposed surface of the abraded paint; and polishing the outwardly exposed surface of the applied clear coat to form a repaired portion of the paint film.SELECTED DRAWING: Figure 1

Description

[Background technology]

[0001] Film-like paints have been developed for application to surfaces as a replacement for traditional paints. Traditional paints are typically liquid-based and applied to surfaces in liquid form (e.g., spray application). Film-like paints are based on at least one polymer layer and may also be referred to herein as "polymer films" or "polymer paint films." One example of such a polymer paint film is described in U.S. Patent No. 10,035,932, entitled "Paint Replacement Films, Their Composites, and Related Methods." However, unlike the paint replacement films described therein, many traditional paint films contain low surface energy materials (e.g., fluoropolymers and / or silicones) that resist coatings and other materials from adhering to the paint film. See, for example, U.S. Patent No. 5,965,256. While such resistance can be advantageous, for example, when stain resistance is desired, it can also make it difficult to apply desired additional coatings to the paint film once it has been applied to a surface. For example, applying an additional coating of a liquid-based paint can be useful to repair a paint film to hide imperfections caused by wear and tear associated with use of the article to which the paint film is applied. However, due to problems with the adhesion of such coatings to many conventional paint films, methods for successfully repairing a paint film once it has been applied to a surface have not yet been successfully developed. [Prior art documents] [Patent documents]

[0002] [Patent Document 1] U.S. Patent No. 10,035,932 [Patent Document 2] U.S. Patent No. 5,965,256 Summary of the Invention [Problem to be solved by the invention]

[0003] While not limited in scope to such paint films, the method of the present invention is particularly useful for paint films that do not essentially contain low surface energy materials, facilitating the repair of such paint films. Furthermore, the method of the present invention finds beneficial application for improving the efficiency of repairing paint films that are applied onto an underlying substrate using an adhesive. Typically, such an underlying substrate is preformed, for example, into a desired shape, as opposed to a substrate that is otherwise formed in the presence of a paint film that may not include an adhesive layer. [Means for solving the problem]

[0004] In accordance with the present invention, a method for repairing a paint film originally applied to a base substrate using an adhesive comprises the following series of steps: removing one or more damaged portions of the paint film from the base substrate to expose the damaged areas; sanding the surface of the adjacent portions of the paint film adjacent the base substrate where the paint film is no longer uniformly adhered; applying a filler material to the damaged areas and covering any exposed edges of the adjacent portions of the paint film; sanding the outer exposed surface of the filler material; and adhering the surface to the outer exposed surface of the sanded filler material and the paint film. applying a primer to the adjacent portion; sanding the exposed surface of the primer; applying paint to the adjacent portion of the sanded primer and the paint film; sanding the exposed surface of the paint; applying a clearcoat to the exposed surface of the sanded paint; and finish sanding the exposed surface of the applied clearcoat to form a repaired portion of the paint film, which results in a repaired paint film on the underlying substrate. [Brief explanation of the drawings]

[0005] [Figure 1] Figure 1 is a schematic cross-sectional view of an exemplary paint film adhered to an underlying substrate, shown before the paint film is damaged and repaired by the method of the present invention. [Figure 2A] FIG. 2A is a schematic cross-sectional view of an exemplary paint film adhered to an underlying substrate, similar to FIG. 1, but in this illustration, the paint film is shown to include a damaged area requiring repair. [Figure 2B] FIG. 2B is a schematic cross-sectional view of the paint film and underlying substrate of FIG. 2A, where the damaged area of ​​the paint film has been removed by steps of a method according to the present invention. [Figure 2C]FIG. 2C is a schematic cross-sectional view of the paint film and underlying substrate of FIG. 2B, where the damaged area of ​​the underlying substrate and the surface of the adjacent portion of the paint film have been polished by steps of a method according to the present invention. [Figure 2D] FIG. 2D is a schematic cross-sectional view of the paint film and underlying substrate of FIG. 2C, but in which a filler material has been applied to the sanded substrate and adjacent portions of the paint film by steps of a method according to the present invention. [Figure 2E] FIG. 2E is a schematic cross-sectional view of the paint film and underlying substrate of FIG. 2D, but in which the exposed surface of the filler has been polished in accordance with a method step of the present invention. [Figure 2F] FIG. 2F is a schematic cross-sectional view of the paint film and underlying substrate of FIG. 2E, but in this illustration, a primer has been applied to the outer exposed surface of the sanded filler in accordance with a method step of the present invention. [Figure 2G] FIG. 2G is a schematic cross-sectional view of the paint film and underlying substrate of FIG. 2F, but in this illustration, the exposed surface of the primer has been sanded down by a step in the method of the present invention. [Figure 2H] FIG. 2H is a schematic cross-sectional view of the paint film and underlying substrate of FIG. 2G, but in this illustration, paint has been applied to the outer exposed surface of the sanded primer by a method step according to the present invention. [Figure 2I] FIG. 2I is a schematic cross-sectional view of the paint film and underlying substrate of FIG. 2H, where the exteriorly exposed surfaces of the paint and adjacent portions of the paint film have been polished by steps of the method of the present invention. [Figure 2J] FIG. 2J is a schematic cross-sectional view of the paint film and underlying substrate of FIG. 2I, but showing a clear coat applied to the exteriorly exposed surface of the sanded paint and adjacent portions of the paint film in accordance with a method step of the present invention. [Figure 2K]FIG. 2K is a schematic cross-sectional view of the paint film and underlying substrate of FIG. 2J, but in this illustration, the clear coat has been polished according to a method step of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0006] As noted in the Background section, paint films are increasingly being used to apply color to surfaces. Paint films generally include at least an exposed transparent layer (also called a clear coat layer) and an underlying color layer (a color layer that serves as a base). As shown in FIG. 1, a paint film 100 is often adhered to an underlying substrate 102 using an adhesive layer 104, which is located on one side of a color layer 106 opposite a transparent layer 108.

[0007] In order to repair any damage that may have occurred to the paint film, the method of the present invention is the first of its kind to make it possible to repair a paint film by substantially removing only the damaged portion of the paint film. According to the method of the present invention, the paint film is repaired using a method comprising the steps described below.

[0008] FIG. 2A illustrates a damaged paint film 200, comprising an adhesive layer 204, a color layer 206, and a clear layer 208. According to this method, one or more damaged portions 210 of the paint film 200 (including any adjacent areas of the paint film 200 that may be incidentally included to facilitate repair) are first removed from the underlying substrate 202. FIG. 2B illustrates the paint film 200 with the damaged portions 210 removed. The damaged portions of the paint film 200 can be removed using any suitable mechanism (e.g., by cutting with a razor blade or by other methods). Advantageously, using the method of the present invention to repair a paint film surface does not require removing and discarding the entire sheet of paint film 200, including the damaged portions 210, from the surface.

[0009] Once the damaged portion 210 is removed, the damaged area 212 (i.e., the portion of the underlying substrate 202 where the paint film 200 is no longer uniformly adhered) and adjacent portions of the paint film 200 are polished to a desired surface using a first polishing step. Any suitable mechanism can be used to create the polished surface 214 shown in FIG. 2C. In an exemplary embodiment, polishing by sanding can be facilitated using a dual-action (e.g., random orbit) sander. One example of a useful sander according to the present invention is an orbital sander sold under the trade name 3M™ 20331 by 3M Company, St. Paul, Minnesota. Any suitable sandpaper can be used for this and other steps of the method according to the present invention. For example, a useful sandpaper is gold and purple sandpaper sold under the trade name 3M™ Hookit™ by 3M Company, St. Paul, Minnesota. According to an exemplary aspect of this embodiment, sandpaper having a grit of approximately 240 is used in this step. In another exemplary embodiment, polishing is performed using a separate polishing pad in addition to or instead of sandpaper. Various polishing pads are known and can be used for this process. Among these polishing pads are, for example, red polishing pads sold under the SCOTCH-BRITE brand by 3M Company (St. Paul, Minnesota) (e.g., SCOTCH-BRITE™ Hand Pad 7447, etc.).

[0010] After the first sanding step, a filler material 216 is applied to fill the damaged area 212 and cover any exposed edges 218 of the adjacent portion of the paint film 200, as shown in FIG. 2D. Any number of coats of suitable filler material 216 may be applied to achieve the desired coverage. In an exemplary embodiment, two to three coats of filler material are used for this purpose. A variety of suitable filler material 216 materials are known and can be used for this step, including a self-leveling finishing glaze sold by 3M Company, St. Paul, Minnesota, as 3M™ Platinum™ Plus Glaze (e.g., 3M Part No. 31180) and BONDO brand body filler, also sold by 3M Company, St. Paul, Minnesota.

[0011] After the filling step, as shown in FIG. 2E, a second sanding step is performed to smooth the filler material 216 on the surface 222 of the damaged area 212 and the adjacent portion of the paint film 200 (e.g., in one embodiment, about 1 inch to about 3 inches of the undamaged adjacent portion of the paint film 200 is sanded in this second sanding step). In one embodiment, the second sanding step includes sanding with progressively finer sandpaper 200. Any suitable number and size of sandpaper grits can be used in this second sanding step. In an exemplary embodiment, a series of sandpapers 220 with 180 grit, 240 grit, 320 grit, and 500 grit, followed by 800 grit, are used in this second sanding step.

[0012] After the second sanding step, at least one layer of primer 224 is applied to the sanded filler 216 and adjacent portions of the paint film 200 (which adjacent portions were also sanded in the second sanding step), as shown in Figure 2F. Various primers 224 are known and can be used in this step, such as, for example, a 2K-urethane primer-surface treatment sold under the trade name P30-SpectraPrime™ by The Sherwin-Williams Co. (Warrensville Heights, Ohio).

[0013] After the primer 224 is set up, the primer 224 is sanded in a third sanding step, for example, using sandpaper 226 containing any suitable number and size of sandpaper grit, as shown in Figure 2G. In an exemplary embodiment, the primer 224 and adjacent portions of the paint film 200 (e.g., in this third sanding step according to one embodiment, about 1 inch to about 3 inches of the adjacent portion of the undamaged paint film 200 is sanded) are gradually wet-sanded with 400-grit and 800-grit sandpaper 226.

[0014] Next, as shown in FIG. 2H, paint 228 is applied to the sanded primer 230 and the sanded areas 232 of the adjacent portions of the paint film 200. In an exemplary embodiment, the paint 228 is applied in liquid form to the sanded primer 230 and the adjacent sanded areas 232 according to this process. Various paints 228 are known and can be used for this process, such as a base coat sold under the trade name Deltron™ DBC (e.g., Deltron™ 2000 DBC) by PPG Industries Ohio, Inc. (Cleveland, Ohio). Preferably, the paint 228 matches in color the exterior, exposed appearance of the paint film 200. The appearance of the paint film 200 is primarily expressed by the color layer 206. Multiple coatings of the paint 228 may be useful to achieve desired aesthetic and protective properties.

[0015] After the paint 228 has dried, as shown in FIG. 2I, the paint 228 and adjacent portions of the paint film 200 are surface abraded according to a fourth abrading step (e.g., in one embodiment, in this fourth abrading step, about 1 inch to about 3 inches of the adjacent, undamaged paint film 200 surface is abraded), and further sanded using a 3000-grit abrasive 234 (e.g., a 3000-grit abrasive disc sold by 3M Company, St. Paul, Minnesota, as 3M™ Trizact™ Hookit™ Foam Abrasive Disc).

[0016] 2J, a clearcoat 236 is then applied to cover the entire area where the paint 228 was applied in the previous step. Various clearcoats 236 are known and can be used in this step, including, for example, the clearcoat 236 sold by PPG Industries Ohio, Inc. (Cleveland, Ohio) under the Deltron™ DC trade name (e.g., Deltron™ DC2000 and Deltron™ DC4000).

[0017] Once dried, the clear coat 236 is finish sanded using any suitable mechanism desired to achieve the desired aesthetics and any desired protective properties in the repaired portion of the paint film, as shown in Figure 2K. In an exemplary embodiment, a wool bonnet 238 and a finish sander 240 are used in this step.

[0018] The method of the present invention can be used to repair any conventional paint film, including those described in U.S. Pat. No. 10,035,932, those sold by Entrotech, and those marketed by related entities under the AERO and related brand names. The method of the present invention is particularly useful in the transportation vehicle industry. For example, the method is advantageously used to repair automotive paint films, particularly those applied by original equipment manufacturers (OEMs) onto automobiles or other transportation vehicles. According to one aspect of the exemplary embodiment, the repaired portion of the paint film has a gloss value within 5 gloss units of the gloss value of the originally applied paint film when tested in accordance with DIN EN ISO 2813. According to another aspect of the exemplary embodiment, the repaired portion of the paint film has a color reading of 3 or less delta E when tested in accordance with DIN EN ISO 11664.

[0019] Various modifications and alterations to the present invention will become apparent to those skilled in the art without departing from the spirit and scope of the invention, which is defined by the appended claims. For example, when referring to "sandpaper," it is understood that any suitable abrasive material may be used and need not necessarily be in the form of paper itself. Furthermore, the absence of a recitation or description of a feature, step, or structure provides a basis for a claim in which the absent feature or structure is excluded by disclaimer or similar language.

Claims

1. 1. A method for repairing a paint film originally applied to an underlying substrate using an adhesive, comprising the following series of steps: removing one or more damaged portions of the paint film from the underlying substrate to expose damaged areas; sanding the surface of adjacent portions of said paint film adjacent portions of the underlying substrate to which said paint film is no longer uniformly adhered; applying a filler material to the damaged area and covering any exposed edges of the adjacent portion of the paint film; polishing the outer exposed surface of the filler; applying a primer to the outwardly exposed surfaces of said sanded filler and adjacent portions of said paint film; sanding the outwardly exposed surface of the primer; applying paint to the outwardly exposed surface of the sanded primer and adjacent portions of the paint film; sanding the exteriorly exposed surface of the paint; applying a clear coat to the exposed surface of the sanded paint; and polishing the outwardly exposed surface of the applied clear coat to form a repaired portion of the paint film; wherein these steps result in a repaired paint film on the underlying substrate.

2. The method of claim 1 , wherein the underlying substrate is preformed into a desired shape.

3. 10. The method of claim 1, wherein the step of removing one or more damaged areas of the paint film includes removing any adjacent areas of the paint film that may be incidentally included to facilitate repair.

4. 10. The method of claim 1, wherein the paint film is essentially free of low surface energy materials.

5. 10. The method of claim 1, wherein the one or more damaged portions of the paint film are removed using a cutting mechanism.

6. 10. The method of claim 1, wherein the entire sheet of paint film having the damaged portion is not removed from the substrate during the paint film repair method.

7. 10. The method of claim 1, wherein any of the steps of abrading the surface includes sanding with a dual action sander.

8. 10. The method of claim 1, wherein any of the steps of abrading the surface includes sanding with an orbital sander.

9. 10. The method of claim 1, wherein any of the steps of polishing the surface includes using a polishing pad.

10. 10. The method of claim 1, wherein the step of applying a coating comprises applying a wet-applied type coating.

11. 10. An article comprising the repaired paint film on the underlying substrate by the method of claim 1.

12. 12. The article of claim 11, wherein the base substrate comprises an exterior surface of a transportation vehicle.

13. 12. The article of claim 11, wherein the repaired portion of the paint film has a gloss value within 5 gloss units of the gloss value of the originally applied paint film when tested in accordance with DIN EN ISO 2813.

14. 12. The article of claim 11, wherein the repaired portion of the paint film, when tested in accordance with DIN EN ISO 11664, has a color reading of Delta E of 3 or less.

Images