Method of forming multi-layered patterned coating film

Abstract

The present invention provides methods of forming multi-layered patterned coating films comprising the steps of (1) applying a first colored base coating composition to a substrate, (2) applying a second colored base coating composition over the uncured coating film of the first colored base coating composition in such a manner that the first colored base coating film is partially exposed, the second colored base coating composition being able to form a coating film of different color and/or visual texture from that of the first colored base coating composition, and having, 30 seconds after application, 30 to 60 mass % of the solids content of the base coating composition, and (3) applying a top clear coating composition over the cured or uncured first and second colored base coating compositions, and curing the uncured composition(s).

Description

Claims

1. A method of forming a multi-layered patterned coating film comprising the steps of (1) applying a first colored base coating composition to a substrate,(2) applying a second colored base coating composition over the uncured coating film of the first colored base coating composition in such a manner that the first colored base coating film is partially exposed, the second colored base coating composition being able to form a coating film of different color and/or visual texture from that of the first colored base coating composition, and having, 30 seconds after application, 30 to 60 mass % of the solids content of the base coating composition, and(3) applying a top clear coating composition over the cured or uncured first and second colored base coating compositions, and curing the uncured composition(s).

2. A method of forming a coating film according to claim 1, wherein the second colored base coating composition is a luster coating composition.

3. A method of forming a coating film according to claim 1, wherein two or more kinds of coating compositions capable of forming a coating film of different colors and/or visual textures are applied as the second colored base coating composition.

4. A method of forming a coating film according to claim 3, wherein a spray gun equipped with a plurality of coating nozzles is employed to apply the two or more kinds of coating-compositions.

5. A method of forming a coating film according to claim 1, wherein the proportion of area exposed of the first colored coating film after the application of the second colored base coating composition is about 1% to about 95%.

6. A method of forming a coating film according to claim 1, wherein the colors and/or visual textures of the coating films obtained by individually applying the first and second colored base coating compositions meet at least one requirement selected from the group consisting of (i) the lightness value difference, ΔL*, is 5 or higher on the L*C*h Color Scale, (ii) the hue angle value difference, Δh, is 45 or higher on the L*C*h Color Scale, and (iii) the flip-flop value difference, ΔFF, is 0.2 or higher.

7. A method of forming a coating film according to claim 1, wherein the uncured coating film of the first colored base coating composition in step (2) has a solids content of 40 mass % or greater.

8. A method of forming a coating film according to claim 1, wherein in step (3) the first and second colored base coating films are cured, and the top clear coating composition is then applied over these films and cured.

9. A method of forming a coating film according to claim 1, wherein in step (3) the first and second colored base coating composition films are left uncured, and the top clear coating composition is then applied over these coating films, and these three coating film layers are cured simultaneously.

10. A method of forming a coating film according to claim 1, wherein the top clear coating composition contains a gloss control agent.

11. A method of forming a coating film according to claim 1, wherein the substrate is an automotive body or automobile interior part.

12. A coated product on which a patterned coating film is formed by the method of forming a multi-layered patterned coating film according to claim 1.