Radiation polymerizable coating composition containing an unsaturated phosphoric ester

More particularly, this application relates to radiation polymerizable coating compositions which are particularly suited as corrosion and abrasion resistant protective coatings for vapor deposited metal surfaces as well as to articles comprising such a vapor deposited metal surface bearing the protective coating and processes for preparing the same. Such protectively coated, vapor deposited metal bearing articles are a particularly preferred embodiment of the invention since they are suitable for use as a substitute for plated metal surfaces used for trim or brightwork on the exterior of automobiles.
The radiation polymerizable coating compositions disclosed in concurrently filed application entitled "Protective Coating Composition, Plural Coated Article and Process for Making Same - A", which is a Continuation-in-Part of both Ser. No. 393,702, filed Aug. 31, 1973 and now developed and Ser. No. 431,633 filed Jan. 8, 1974 and now abandoned, form coatings of excellent quality which display unusually good abrasion resistance. While the outstanding properties of those compositions effectively solve many of the problems associated with providing protective coatings for a variety of substrates, and in particular for substrates bearing vapor deposited metals, they do not provide adequate corrosion and water resistance to allow exterior automotive use of vapor metallized materials.
The coating compositions of this invention solve such problems by providing improved corrosion and water resistance.
BRIEF DESCRIPTION OF THE INVENTION
The coating compositions of this invention, on a non-polymerizable solvent, pigment, initiator and particulate filler-free basis consist essentially of a binder solution of: (1) between about 90 and about 10 parts of a saturated, thermoplastic vinyl polymer prepared from at least about 85 weight percent of monofunctional vinyl monomers; (2) between about 10 and about 90 parts of vinyl solvent monomers for said vinyl polymer, at least about 10 weight percent, preferably at least about 30 weight percent, of said solvent monomers being selected from the group consisting of divinyl monomers, trivinyl monomers, tetravinyl monomers and mixtures thereof; and (3) between about 0.05 and about 1.0 parts per 100 parts of the total of said thermoplastic, vinyl polymer and said vinyl solvent monomers of a mono- or diester of phosphoric acid bearing one or more sites of vinyl unsaturation and having the formula: ##STR1## where: R = H, Cl or CH.sub.3
A = c.sub.n H.sub.2n, 2.ltoreq.n .ltoreq.6
R'=h, c.sub.1 to C.sub.4 alkyl or
C.sub.1 to C.sub.4 chloro- or bromo-alkyl
These coating compositions, which are radiation polymerizable, are preferably cured by exposure to ionizing radiation or ultraviolet radiation. The coating compositions provide an excellent protective surface which adheres well to a variety of substrates, in particular metals and vapor deposited metals, and, thus, can be employed in the preparation of a wide variety of articles. One such preferred article or material, which is useful as a substitute for metal plated materials used for trim or brightwork on the exterior of automobiles, is prepared by: (1) vapor depositing a metal layer on the surface of a prepared substrate; (2) coating the deposited metal surface with the radiation polymerizable coating of this invention; and (3) curing the coating by exposure to radiation, preferably ionizing radiation or ultraviolet radiation.
The radiation polymerizable coating composition and the coated articles formed therefrom as well as the processes for preparing the same will be described more fully in the detailed description of the invention which follows.
PRIOR ART
An article entitled "Radiation Curing of Mixture of Diallylphthalate Prepolymer and Vinyl Monomer" by Gatoda et al appearing at Nippon Genshiryoku Kenkyusho Nempo 1970, JAERL/5026, 121-9 (Japan) discloses radiation polymerizable coating compositions which may contain several of the organophosphate esters within the purview of this invention. The article further teaches the strong adhesion of the diallylphthalate prepolymer-vinyl monomer-organophosphate ester coatings to metal surfaces as a shop primer to prevent corrosion. However, the article teaches the use of the organophosphate esters only in amounts equal to or greater than 2 weight percent based on the total of the other two components. In this connection the article also teaches that as the amount of organophosphate ester is increased the salt water resistance of the coating is increased. These teachings are contrary to the instant invention which, as mentioned above, requires between about 0.05 and about 1.0 parts of organophosphate ester per 100 parts of the total of the thermoplastic vinyl polymer and vinyl solvent monomers. In fact, it has been found quite unexpectedly that while the organophosphate esters when included in the coatings of the invention in amounts up to 1% by weight serve to protect the underlying metal from corrosive or chemical attack, amounts greater than 1% by weight and certainly amounts of 2% by weight or greater cause the coating composition to fail in water.
DETAILED DESCRIPTION OF THE INVENTION
I. Radiation Polymerizable Coating Composition
In this application, the term "paint" is meant to include finely divided pigment and/or particulate filler as well as other additives in a film-forming, resin comprising, binder or the binder without pigmet, particulate filler, and other additives. Thus, the binder which is ultimately converted to a weather and wear-resistant film can be all or virtually all that is used to form the film, or it can be a vehicle for pigment and other additives.
Prior art radiation polymerizable paints conventionally comprise a solution of an alpha-beta olefinically unsaturated prepolymer in vinyl monomers. Exemplary of such prior art radiation polymerizable coatings are those disclosed in the following U.S. Pat. Nos: 3,437,512; 3,437,513; 3,437,514; 3,528,844; 3,542,586; 3,582,587; 3,560,245; 3,577,262; 3,577,263; 3,577,264, 3,577,265; 3,585,526; 3,586,527; 3,586,528; 3,586,529; 3,586,530; 3,586,531; 3,591,626; 3,595,687; 3,632,399; 3,632,400; 3,641,210; 3,642,939; 3,649,337; 3,650,811; 3,650,812; 3,650,813; 3,660,143, 3,660,144; 3,660,145; 3,660,371; and 3,679,447. In these patents, the alpha-beta olefinically unsaturated prepolymer is defined as having olefinic unsaturation provided by an alpha-beta olefinically unsaturated monomer; or more particularly, as a resin having pendant unsaturation or olefinic unsaturation between the two terminal carbons of a polymer side chain. It is this pendant unsaturation which permits the prepolymer to not only polymerize with vinyl solvent monomers, but also to crosslink and thus form a tough solvent and weather-resistant coating. Other paints which are radiation polymerizable at low radiation dosages and which comprise monounsaturated monomers and a saturated prepolymer containing from about 25 to about 65 mole percent of certain hydroxy acrylates have been disclosed in U.S. Pat. application Ser. No. 295,649, filed Oct. 6, 1972 and now abandoned. Still other paints which are radiation polymerizable and which comprise conventional alpha-beta olefinically unsaturated prepolymers and vinyl monomers in combination with between about 5 and about 25 weight percent based on the total formula weight of the paint of a saturated, thermoplastic vinyl resin are disclosed in U.S. Pat. application Ser. No. 375,992 filed July 2, 1973 now U.S. Pat. 3,895,171.
While each of the discussed prior art coatings exhibits a variety of excellent properties, each suffers from certain disadvantages. Polymers bearing polymerizable unsaturation, i.e., alpha olefinic unsaturation, are generally prepared by at least a two-stage synthesis which is time consuming and expensive. Polymers bearing hydroxyl functionality can be prepared by a single stage synthesis, but at the hydroxyl levels required for effective crosslinking (25 to 65 mole percent), the water resistance of the final cured film is significantly impaired.
The radiation polymerizable coating compositions of this invention, which overcome the deficiencies of prior art coatings, on a non-polymerizable solvent, pigment, initiator and particulate filler-free basis, consist essentially of: (1) between about 90 and about 10 parts of a saturated, thermoplastic vinyl polymer prepared from at least about 85 weight percent of monofunctional vinyl monomers; (2) between about 10 and about 90 parts of vinyl solvent monomers for said vinyl polymer, at least about 10 weight percent, preferably at least about 30 weight percent, of said solvent monomers being selected from the group consisting of divinyl monomers, trivinyl monomers, tetravinyl monomers and mixtures thereof; and (3) between about 0.05 and about 1.0 parts per 100 parts of the total of said thermoplastic, vinyl polymer and said vinyl solvent monomers of a mono- or diester of phosphoric acid bearing one or more sites of vinyl unsaturation and having the formula: ##STR2## where: R = H, Cl or CH.sub.3
A = c.sub.n H.sub.2n, 2 .ltoreq. n .ltoreq. 6
R'= h, c.sub.1 to C.sub.4 alkyl or
C.sub.1 to C.sub.4 chloroalkyl or bromoalkyl
A. Saturated, Thermoplastic, Vinyl Resin Polymer
The saturated, thermoplastic, vinyl resin polymers useful in the paint compositions of this invention may be prepared from a single vinyl monomer or from mixtures of vinyl monomers by conventional polymerization techniques, e.g., suspension, emulsion, bulk or solution polymerization using conventional free radical initiators such as peroxides and hydroperoxides as well as azobis(isobutyronitrile). The term "vinyl monomer" as used herein refers to a monomeric compound having a ##STR3## terminal group and excludes allylic compounds. Preferred monomers for preparation of the vinyl homopolymer or copolymer resins are monofunctional monoacrylates and monomethacrylates as well as monovinyl hydrocarbons. The most preferred monomers are esters of acrylic or methacrylic acid and C.sub.1 -C.sub.8 monohydric alcohols, e.g., methyl methacrylate, butyl methacrylate, butyl acrylate, 2-ethylhexyl acrylate, cyclohexyl acrylate and mixtures thereof. Monovinyl hydrocarbons suitable for use in forming polymers are styrene and substituted sytrenes, such as alpha-methyl styrene, vinyl toluene, t-butyl styrene, chlorostyrene and mixtures thereof.
As indicated above, the saturated thermoplastic vinyl resin polymers or copolymers useful in paints of this invention should be formed from at least 85 weight percent of monofunctional vinyl monomers. However, difunctional monovinyl monomers such as acrylic and methacrylic acids, acrylamide, methacrylamide, 2-hydroxyethyl methacrylate, methacryloyloxyethyl phosphate and 2-acrylamido-2-methylpropanesulfonic acid, may be used as a minor component of the polymer, i.e., up to a combined total of about 15 weight percent. The incorporation of such monomers may be desirable in some cases to provide a measure of polarity to the coating resin. However, it should be recognized that a concomitant effect of increased polarity is increased water sensitivity. Thus, it is preferred not to employ such polar monomers in the preparation of the paints of this invention unless necessary for the particular application.
The essentially linear, gel-free thermoplastic polymers formed from the preferred monomers set forth above should have number average molecular weights (M.sub.n) of less than about 250,000 but not less than about 2,000. Preferred values lie between about 3,000 and about 100,000 with most preferred values being between about 5,000 and about 50,000.
While the paint composition of the invention may include mixtures of polymers or copolymers formed from vinyl monomers as discussed above, it is preferred that the paint solution contain little or no alpha-beta olefinically unsaturated resins as conventionally employed in radiation-curable paint resins discussed above. The term "alpha-beta olefinically unsaturated resin" as used in this context is intended to mean an organic resin having olefinic unsaturation provided by an alpha-beta olefinically unsaturated monomer. More specifically the term is intended to mean olefinic unsaturation between the two terminal carbons of a polymer side chain. Even though the properties of the paint, particularly adhesion properties, will be affected by its inclusion, up to 5 weight percent based on the total of polymer and solvent monomer of such alpha-beta olefinically unsaturated resins may be tolerated.
B. Vinyl Solvent Monomers
At least about 10 weight percent and preferably at least about 30 weight percent of the vinyl solution monomers of the paint compositions of this invention are selected from the group consisting of divinyl monomers, trivinyl monomers, tetravinyl monomers and mixtures thereof. These di-, tri-, and tetravinyl compounds are preferably acrylates, methacrylates or vinyl hydrocarbons. The most preferred are esters of acrylic or methacrylic acids an polyhydric C.sub.2 -C.sub.8 alcohols, e.g., neopentylglycol dimethacrylate, 1,6-hexanediol diacrylate, 1,3-butylene dimethacrylate, tri-methylolpropane triacrylate, pentaerythritol triacrylate, pentaerythritol tetraacrylate, etc. Other divinyl monomers which may be employed are disclosed in U.S. Pat. Nos. 3,586,528; 3,586,529; 3,586,530; 3,586,531; and 3,595,687. These divinyl compounds are formed by reacting either a monoepoxide or diepoxide with acrylic acid or methacrylic acid and subsequently reacting the resultant ester condensation product with a saturated acyl halide. Further tetravinyl compounds which may be employed are disclosed in U.S. Pat. Nos. 3,586,526; 3,586,527; and 3,591,626. These tetravinyl compounds are formed by reacting a diepoxide with acrylic acid and/or methacrylic acid and then subsequently reacting the resultant ester condensation product with a vinyl unsaturated acyl halide.
The remainder of the vinyl solvent monomers used in combination with the saturated, thermoplastic vinyl resin polymers or copolymers discussed above may be monofunctional, monovinyl monomers such as those used in the preparation of the polymer or copolymer. C. Mono- or Diesters of Phosphoric Acid
The coating compositions of the invention include between about 0.05 and about 1.0 parts, preferably between about 0.1 and about 0.6 parts, and more preferably between about 0.2 and about 0.5 parts, per 100 parts of the total of said saturated, thermoplastic, vinyl resin polymer and said vinyl solvent monomers of a mono- or diester of phosphoric acid bearing one or more sites of vinyl unsaturation and having the formula: ##STR4## where: R = H.sub.1 Cl or CH.sub.3
A = c.sub.n H.sub.2n, 2.ltoreq. n .ltoreq. 6
R'=h.sub.1 c.sub.1 to C.sub.4 alkyl or C.sub.1 to C.sub.4 chloro- or bromo- alkyl
Representative of the various species of organophosphate esters falling within the above formula are: (1) 2-methacryloyloxyethyl phosphate (R=CH.sub.3, A= --CH.sub.2 CH.sub.2 --, R'=H, m=1); (2) di(2-methacryloyloxymethyl) phosphate (R=CH.sub.3, A= --CH.sub.2 CH.sub.2 --, m=2); (3) 2-acryloyloxyethylphosphate (R=H, A= --CH.sub.2 CH.sub.2 -, R'=H, m=1); (4) di(2-acryloyloxyethyl)phosphate (R=H, A= --CH.sub.2 CH.sub.2 --, m=2); (5) methyl 2-methacryloyloxyethyl phosphate (R=CH.sub.3, A=CH.sub.2 CH.sub.2 -, R'=CH.sub.3, m=1); (6) ethyl methacryloyloxyethyl phosphate (R=CH.sub.3, A= -CH.sub.2 CH.sub.2 -, R'=CH.sub.3 CH.sub.2 --, m= 1); (7) methyl acryloyloxyethyl phosphate (R=H, A= --CH.sub.2 CH.sub.2 --, R'=CH.sub.3, m=1); and (8) ethyl acryloyloxyethyl phosphate (R=H, A.hoarfrost.CH.sub.2 CH.sub.2 -, R'=CH.sub.3 CH.sub.2 --, m=1).
The preferred organophosphate esters are 2-methacryloyloxyethyl phosphate, di(2-methacryloyloxyethyl) phosphate, 2-acryloyloxyethyl phosphate and di(2-acryloyloxyethyl) phosphate, with 2 methacryloyloxyethyl phosphate being most preferred. Exemplary of the many other organophosphate esters which are encompassed by the above formula are those in which the R' groups of (1) through (8) are replaced by propyl butyl and isobutyl groups or by chloro or bromo substituted ethyl, propyl, butyl and isobutyl groups.
D. Photoinitiators
When the paint compositions of this invention are polymerized by exposure to ultraviolet radiation it may be desirable to include a photoinitiator or photosensitizer in the paint. The use of such photoinitiators and examples of various ones which may be employed will be discussed hereinafter in greater detail.
E. Inert Solvents and Other Additives
Inert solvents, i.e., solvents that do not enter into the polymerization or crosslinking reactions of the paint binder polymer/monomer system under normal exposure to radiation, can be added to the coating formulation to reduce viscosity and aid in control of application properties. Such solvents are normally selected to be substantially more volatile than the monomeric constituents of the paint formulation, thus allowing them to evaporate prior to irradiation of the coatings. Suitable solvents include, by way of example and not by way of limitation: toluene; butyl acetate; methylethyl ketone; isopropanol; benzene; tetrahydrofuran; dioxane, methylisobutyl ketone; methylene chloride; chloroform; ethylene chloride; trichloroethylene; trichloroethane; and mixtures thereof. Additional materials such as catalysts, pigments, plasticizers etc., all of which are well known in the formulation of coating compositions and, in particular in the art of radiation polymerizable coating compositions, may be included in the coating compositions of the invention.
II. Coated Articles and Processes for Making Same
The radiation polymerizable paints discussed above display unusually good adhesion to a variety of substrates including wood, paper, glass, shaped polymeric surfaces and metal, particularly vapor deposited metal surfaces. In addition to these outstanding adhesion properties, the coatings of the invention also exhibit excellent water resistance and intercoat adhesion. The novel paint compositions of the invention, like prior art radiation polymerizable paints discussed above, may be applied to a variety of substrates by conventional means, e.g., brushing, spraying, roller coating, flow coating, etc., to an average thickness which is preferably in the range of from about 0.1 to about 4.0 mils depending on the substrate and the intended end use of the coated product.
The novel paint compositions of the invention may be cured or polymerized by exposure to radiation, preferably ionizing radiation or ultraviolet light. In either case, the paint compositions may be cured at relatively low temperatures, e.g., between room temperature (20 to 25.degree. C) and the temperature at which significant vaporization of its most volatile component is initiated, (ordinarily between about 20.degree. C and about 70.degree. C).
The term "ionizing radiation" as employed herein means radiation having sufficient energy to remove an electron from a gas atom, forming an ion pair, and hence radiation with energy of, or equivalent to, about 5,000 electron volts. The preferred method of curing paint films of this invention by exposure to ionizing radiation is by subjecting such films to a beam of polymerization-effecting electrons which is at its source of emission within the range of, or equivalent to, 150,000 to 450,000 electron volts. In this method of curing, it is preferred to employ a minimum of 25,000 electron volts per inch of distance between the radiation emitter and the workpiece where the intervening space is occupied by air. Adjustment is made for the resistance of the intervening gas which is preferably an oxygen-free inert gas such as nitrogen, helium, or combustion products of natural gas. It is, however, within the scope of the use of ionizing radiation to effect polymerization using either that which is conventionally termed "high energy particle radiation" or "ionizing electromagnetic radiation".
When such ionizing radiation is employed to cure the paint compositions of this invention, the radiation energy is applied at dose rates of from about 0.1 to about 100 Mrads per second upon a preferably moving workpiece with the coating receiving a total dose in the range of from about 0.1 to about 100, preferably from about 1 to about 25 Mrads. The abbreviation "Mrads" as employed herein means 1 million Rads. The term "Rads" means that dose of radiation which results in the absorption of 100 ergs of energy per gram of absorber, e.g., coating film. The electron emitting means may be a linear electron accelerator capable of producing a direct current potentially in the range hereinbefore set forth. In such a device, electrons are ordinarily emitted from a hot filament and accelerated through a uniform voltage gradient. The electron beam, which may be about one-eighth inch in diameter at this point is scanned in one direction to make a fan-shaped beam and then passed through a metal window, e.g., a magnesium-thorium alloy or about 0.003 inch thickness.
As mentioned above, the radiation polymerizable coating compositions of this invention may also be cured by exposure to ultraviolet light. Preferably, paint compositions according to this invention which are cured by exposure to ultraviolet light contain little or no pigment. Upon exposure to light of wave lengths less than about 390 m.mu., most of the vinyl monomers employed in the paint compositions of this invention will fragment and produce radicals which can initiate polymerization. However, in order to make more efficient use of the output of high intensity UV sources and thereby attain a commercially feasible rate of cure, it is preferred to include a photoinitiator or photosensitizer in compositions to be cured by ultraviolet radiation.
Photoinitiators (or sensitizers) are substances, generally organic compounds which, upon exposure to light of appropriate wave length, give rise to or promote the production of polymerization initiating species. It is preferred to employ a photoinitiator which decomposes to yield, or otherwise results in the production of, one or more free radical species upon exposure to light having a wavelength of less than about 380 m.mu.. In order for any photochemical reaction to occur, there must be some overlap between the wave length of light incident upon the reaction medium (the coating) and the wave length absorbed by the photoinitiating species. Thus, the selection of an appropriate photoinitiator depends not only upon its efficacy as a polymerization initiator, but also upon the light source(s) used.
Many different types of free-radical initiators and sensitizers have been studied in acrylic systems and these are well known in the art. The rate of cure of the paint compositions of this invention, is, of course, a function of the type of initiator and its concentration, the intensity of incident light of appropriate wavelength and the type and concentration of polymerization inhibitors. Also, the detailed compositions of the coating formulation can have a significant effect on the rate of cure, especially at low exposure levels. Thus, in the end analysis, the amount of ultraviolet radiation which is necessary to achieve the desired properties in the final film formed from the paint compositions of this invention will vary with the composition of the paint itself and one of ordinary skill in this art will be able to determine the optimal exposure to UV light in view of the various factors discussed above with a minimum of experimentation.
Included among the many suitable photoinitiators are: organic carbonyl compounds such as acetone, benzophenone, benzanthrone, benzoin, benzoin methyl ether, 2,2-diethoxyacetophenone, 2,2-dimethoxy-2-phenylacetophenone, benzoin n-butyl ether and benzoin iso-butyl ether; peroxides such as hydrogen peroxide, di-t-butyl peroxide, ergosterol peroxide and benzoyl peroxide; organic sulphur compounds such as diphenyl disulfides, dibenzoyl disulfides and dibenzothiazol disulfides; and azo compounds such as 2,2' azobis-(2-methylpropionitrile),.alpha.,.alpha.'-azobisisobutyronitrile, azomethane, azothane,.alpha.-azobis-1-cyclohexane carbonitrile; and other well known initiators such as 2-ethylhexyl-2-cyano-3,3-diphenylacrylate. Based on availability, solubility in the coating compositions of this invention, freedom from color and efficiency of curing at minimal UV exposure levels, the preferred photoinitiators are 2,2-diethoxyacetophenone, benzophenone and 2-ethylhexyl-2-cyano -3,3-diphenylacrylate. The amount of each photoinitiator necessary to suitably initiate polymerization in the paint compositions of this invention when curing by exposure to UV light will be apparent to those skilled in the art. It has been found, however, that generally the presence of a photoinitiator in the amount of from about 0.5 to about 5.0 parts per 100 parts of the total reactive vehicle solids in the paint composition will produce adequate curing upon exposure to a low pressure ultraviolet lamp.
A. Coated Articles Including Vapor Deposited Metals
As discussed above, the coating compositions of this invention are particularly suited as abrassion and corrosion resistant protective coatings for surfaces bearing vapor deposited metals. Such coated articles bearing vapor deposited metals are a particularly preferred embodiment of this invention since they are suitable for use as a substituted for plated metal surfaces used for trim or brightwork on the exterior of automobiles.
Vapor deposition of metals, and in particular vacuum metallizing, is a simple and relatively low cost process by which thin layers of metals are deposited on prepared surfaces of substrates such as metal, plastic, glass, paper and other materials. Surfaces bearing vapor deposited metals, and in particular plastic substrates bearing thin deposits of aluminum, have been considered as a substitute for plated metal surfaces used for trim or brightwork on the exterior of automobiles. Since vapor deposition of metals produces very attractive surfaces and is substantially less expensive than processes for metal plating, such as chrome plating, it would appear to be ideally suited for producing such trim or brightwork. However, due to severe abrasion and corrosion problems, articles produced by vapor depositing metals have not been deemed suitable for exterior automotive use. The coating compositions of this invention, when applied over the surface of such vapor deposited metals afford the protection necessary to overcome this problem.
Vapor deposition of metals is well known and the detailed procedures will be apparent to those skilled in the art. Physical vapor deposition, the process most commonly used for decoration of plastics, involves formation of the coating by physical means alone. Two of the most commoly used techniques, i.e., resistive heating and electron beam heating, involve stepwise heating in vacuum, first melting and then vaporizing the material to be deposited. Other well known techniques such as sputtering may also be employed. The choice of methods depends to some extent on the material to be deposited. A review of physical vapor deposition techniques may be found in Vapor Deposition, C. F. Powell, J. H. Oxley and J. M. Blocker, Jr., eds., John Wiley & Sons, Inc. New York (1966), p. 221 ff. Resistive heating of a tungsten filament or basket or of a refractory crucible is commonly used for vapor deposition of aluminum, the most common evaporant for deposition on plastic parts. Electron beam heating of an evaporant contained in a suitable crucible or hearth is recommended for deposition of alloys and metals which have low vapor pressures or which form alloys with conventional filaments or crucibles at normal evaporating temperatures. Iron-chrome alloys can be deposited best using electron-beam heating techniques or sputtering.
Chemical vapor deposition techniques, also discussed in Powell et al, can in principle also be used in the formation of the composite coated articles of this invention. Such techniques involve the transfer of material across temperature or concentration gradients between the substrate and the surrounding atmosphere and formation of coatings by chemical reactions at the surface of the substrate. Chemical vapor deposition techniques often involve heating of the substrate to moderately high temperatures to form the final metallic coating. Application of these techniques is thus restricted to those substrates capable of withstanding the required process conditions.
B. Preferred Plural Coated Embodiment
The preferred coated article of this invention is prepared by: applying a base coat to a substrate and curing the coating; vapor depositing a metal layer on the base coat; applying the coating composition of this invention over the metallized surface; and curing the coating with radiation.
C. Base Coat Compositions
The base coat fills minor surface imperfections of the substrate, provides a high-gloss surface to receive the metal deposit, improves adhesion of the deposit, and reduces the quantity of gas liberated from the substrate at reduced pressures. In selecting a base coat it is thus important that the composition display good intercoat adhesion, i.e., adhere well to both the substrate and the metal layer.
The lacquers and the radiation polymerizable compositions useful as base coats in the process of this invention may be applied by conventional means, e.g., spray coating, dip coating, flow coating, etc., to an average thickness which is preferably in the range of from about 0.1 to about 4.0 mils. The lacquers useful as base coats are well-known in the prior art and may be air dried or heat cured. Most bake-curing lacquers cure in 1-3 hours at temperatures ranging from 140.degree. to 180.degree. F. The radiation polymerizable base coats may be cured at relatively low temperatures, e.g., between room temperature (20.degree. to 25.degree. C) and the temperature at which significant vaporization of its most volatile reactive component is initiated, (ordinarily between about 20.degree. C and about 70.degree. C). The radiation energy is applied at dose rates of from about 0.1 to about 100 Mrads per second upon a preferably moving workpiece with the coating receiving a total dose in the range of from about 0.1 to about 100, preferably from about one to about 25 Mrads. It will be appreciated that the use of radiation polymerizable base coats will substantially lessen the processing time necessary for producing the plural coated articles of the invention.
The lacquer base coats which may be employed are well-known in the art of vapor deposition, and in particular vacuum metallizing, and consist essentially of a crosslinkable or curable resin in a volatile solvent. Representative of the organic resins which may be employed individually or in combination to formulate such a lacquer are: acrylic resins, alkyd resins (pure and modified), polyesters, conventional varnishes, urea-formaldehyde resins, vinyl polymers, acrylonitrile polymers, phenolic resins, cellulosic resins, polyurethanes, butyl rubber and chlorinated butyl rubber, silicone resins, melamine-formaldehyde resins, polyestyrenes, natural rubber, and modified phenolic resins. Numerous base coats employing such organic resins commercially available.
Radiation polymerizable base coat compositions which may be employed in the process and articles of this invention include the composition employed as the radiation polymerizable top coat, i.e., the coating composition of this invention described above in detail. Also, the base coat may be the composition disclosed and claimed in the above-identified application Ser. No. 500,828 entitled "Protective Coating Composition, Plural Coated Article and Process for Making Same-A". That composition corresponds to the composition of this invention with the exception that it does not include the mono- or diester of phosphoric acid.
A still further preferred base coat for the preferred plural coated articles of this invention is the same as the top coat of this invention with the exception that the mono- or diester of phosphoric acid is replaced by a triester in amounts ranging from about 1 to about 15, preferably about 3 to about 10, parts per 100 parts of the total of the thermoplastic vinyl polymer and the vinyl solvent monomers. This triester additive has the formula: ##STR5## where: R = H, Cl or CH.sub.3
A = c.sub.n H.sub.2n, 2 .ltoreq. n .ltoreq. 6
R'= c.sub.1 to C.sub.4 alkyl; C.sub.1 to C.sub.4 bromo- or chloroalkyl; or
Finally, the radiation polymerizable base coat may comprise a film-forming solution which, exclusive of non-polymerizable solvents, pigments and other non-reactive components consists essentially of: (1) between about 90 and about 10 parts, preferably between about 70 and about 30 parts, of an alpha-beta olefinically unsaturated urethane modified organic resin; and (2) between about 10 and about 90, preferably between about 30 and about 70, parts of vinyl solvent monomers, i.e., vinyl monomers which act as solvents for the alpha-beta olefinically unsaturated urethane-modified organic resin. Such a film-forming radiation polymerizable composition is disclosed in U.S. Pat. No. 3,437,514, the entire disclosure of which is incorporated herein by reference.
The alpha-beta olefinically unsaturated urethane-modified organic resin has a molecular weight greater than 1000, preferably between 5000 and 50,000 and still more preferably between 5000 and 20,000 and contains between about 0.5 and about 5, preferably between about 0.5 and about 3, units of olefinic unsaturation per 1000 units of molecular weight. The resin is formed by reacting a diisocyanate monomer and an organic resin having in its molecular structure a plurality of hydrogen atoms which are labile with respect to the isocyanate group, e.g., a labile hydrogen atom of an amine, amide, alcohol or carboxylic acid, and subsequently reacting the product with a hydroxylated vinyl monomer. The organic resin used in the preparation may be a polyester or a resin formed by copolymerization of acrylic monomers, i.e., acrylic and methacrylic acids as well as esters formed therefrom. Exemplary of the many diisocyanates which may be employed to form the alpha-beta olefinically unsaturated resins are: 2,4 tolylene diisocyanate, 65/35 tolylene diisocyanate, 80/20 tolylene diisocyanate, 4,4' Diphenylmethane diisocyanate, dianisidine diisocyanate, tolidene diisocyanate, hexamethylene diisocyanate, etc.
The formulation of various polyesters, such as hydroxy terminated polyesters, and polymers or copolymers formed from acrylic monomers and bearing functional groups which will react with the diisocyanate compounds are well-known in the art. Exemplary of the many monomers which may be employed in the vinyl monomers compound constituent of the urethane-modified base coat are: esters of C.sub.1 -C.sub.8 monohydric alcohols and acrylic or methacrylic acids, e.g., methyl methacrylate, ethyl acrylate, butyl acrylate, butyl methacrylate, octyl acrylate, 2-ethylhexyl acrylate, etc.; esters of alcohols of higher carbon numbers, e.g., C.sub.9 -C.sub.15 as well as difunctional alcohols and acrylic or methacrylic acids; vinyl hydrocarbon monomers, e.g., styrene and alkylated styrenes such as vinyl toluene, alpha-methylstyrene, etc.; divinyl and tetravinyl compounds; and small amounts of other vinyl monomers such as acrylonitrile, acrylamide or vinyl acetate.
The urethane-modified organic resin base coats may also include additives such as pigments, catalysts, inert solvents, etc. as discussed above with respect to top coats.
It should be appreciated that various coating formulations are within the scope of this invention and that such compositions may be applied to various substrates in the manner described. Therefore, it should be understood that the following specific examples are presented by way of illustration and not by way of limitation.

EXAMPLE I
A radiation polymerizable coating is prepared from the following materials in the manner hereinafter set forth:
Step 1______________________________________Preparation of Paint Binder Resin Parts by Weight(1) Water 150(2) Triton X200* 5.2(3) 1% aquous K.sub.2 S.sub.2 O.sub.8 30(4) Methyl methacrylate 300(5) Water 270(6) Triton X200* 3.5(7) Triton X305** 10.7(8) K.sub.2 S.sub.2 O.sub.8 1.2(9) Octanethiol 2.1______________________________________ *Triton X200, a product of Rohm & Haas Co., is an anionic surfactant containing 28% active component (the sodium salt of an alkyl aryl polyester sulfonate). **Triton X305, a product of Rohm & Haas Co., is a nonionic surfactant containing 70% active component (an alkylarylpolyether alcohol averaging 30 ethylene oxide units).
Items 1 and 2 are charged to a reactor provided with a condenser, a thermometer, an agitator, and a dropping funnel. The mixture is boiled to remove dissolved oxygen, and cooled slightly to 90.degree. C. Item 3 is added. A mixture of the remaining ingredients is then added slowly over a period of about 40 minutes while maintaining the reaction mixture at reflux. Following the monomer addition, the mixture is maintained at reflux for an additional two hours.
The latex so obtained is cooled and coagulated by additing it dropwise to three volumes of rapidly stirred methanol heated to about 40.degree. C. The polymeric precipitant is isolated by filtration, washed with methanol, dried in vacuo and used in the subsequent preparation of coating materials. The polymer molecular weight is about 10,000.
Step 2______________________________________Formulation of Coating Parts by Weight(1) Polymer from Step 1 24.2(2) Neopentylglycol diacrylate 36.4(3) 2-ethylhexyl acrylate 39.4(4) 2-methacryloyloxyethyl phosphate .5(5) Butyl acetate 40(6) Toluene 40(7) Methyl ethyl ketone 10(8) Isopropanol 10______________________________________
A solution of polymer is prepared using the above listed monomers and solvents. The film-forming solution so obtained is applied to a plastic substrate bearing a vacuum deposited aluminum surface and cured thereon under an inert atmosphere by electron beam irradiation using a total dosage of 9 Mrads (voltage 275 KV, current 40 ma.).
The coating so obtained displays no softening or color change, and the underlying metal is similarly unaffected by 240 hours exposure to water at 90.degree. F. No failure is observed in 168 hours 5% salt spray exposure. By way of comparison, a similarly prepared coating from which the phosphate additive is omitted, when subjected to similar test conditions, is observed to allow attack on and virtually complete removal of the underlying metal adjacent to a scribed line.
EXAMPLE II
A coating composition is prepared in accordance with the procedures of Example I with the exception that: (1) one part of octanethiol is used in the preparation of the polymer which has a molecular weight (M.sub.n) of about 17,000; (2) .3 parts of di(2-methacryloyloxyethyl) phosphate are employed as the organophosphate ester component; and (3) 3 parts per 100 parts of reactive solids in the coating composition of 2,2 diethoxyacetophenone are added. This coating composition is applied to a substrate comprising a surface of vapor deposited aluminum and cured by exposure to UV light. The coating exhibits excellent abrasion and water resistance.
EXAMPLE III
The procedures of Example I are repeated with the exception that: (1) 4.5 parts of octanethiol are used in the preparation of the polymer which has a molecular weight (M.sub.n) of about 5,000; and (2) .1 parts of 2-acryloyloxyethyl phosphate are employed as the organophosphate ester component. The coating composition, when applied to and cured in situ on a plastic substrate bearing a vapor deposited antimony surface, forms an abrasion and corrosion resistant surface.
EXAMPLE IV
The procedures of Example I are repeated with the difference that: (1) the polymer is formed from an equimolar mixture of isobutyl methacrylate and methyl methacrylate; (2) the inert solvent portion is comprised of equal parts by weight butyl acetate and toluene; and (3) .7 parts of di(2-acryloyloxyethyl) phosphate are employed as the organophosphate ester component. The coating composition is sprayed onto two (2) substrates, one having a surface comprising a vapor deposited alloy of iron and chrome (80% Fe/20% Cr) and the other being a steel panel, and cured by electron beam irradiation. The cured coating adheres well to both surfaces, and is both abrasion and water resistant.
EXAMPLE V
The procedures of Example I are repeated with the exception that: (1) the polymer is formed from an equimolar mixture of ethyl acrylate, styrene, methyl methacrylate and isobutyl methacrylate; and (2) .9 parts of methyl 2-methacryloyloxyethyl phosphate are employed as the organophosphate ester component. The solution is applied to a glass substrate bearing a thin film of vacuum deposited aluminum and cured by electron beam irradiation as in Example I. The surface of the resultant coated article is both abrasion and corrosion resistant.
EXAMPLE VI
The procedures of Example II are repeated with the exception that: (1) the solution monomers are 1,6 hexanedioldiacrylate and 2-ethylhexyl acrylate, present in equal proportions by weight; and (2) .95 parts of ethylmethacryloyloxyethyl phosphate are employed as the organophosphate component. The coating composition is applied to metal, glass, wood and plastic substrates and cured by exposure to UV radiation. The cured coatings are durable and exhibit good adhesion and water resistance.
EXAMPLE VII
The procedures of Example I are repeated with the difference that the film forming solution has the following composition:
______________________________________ Parts by WeightPolymer (from Step 1) 19.5Neopentylglycol diacrylate 43.3Hydroxyethyl acrylate 37.2 methylacryloyloxyethyl phosphate .4______________________________________
The solution is adjusted to spray viscosity by dilution with a mixture of butyl acetate, toluene, methyl ethyl ketone, and isopropanol in proportion by weight 4:4:1:1; sprayed on vapor deposited antimony and cured by exposure to ionizing radiation.
EXAMPLE VIII
The procedures of Example III are repeated with the difference that the film-forming solution has the following composition:
______________________________________ Parts by Weight(1) Polymer (from Step 1) 40(2) Ethyleneglycol dimethacrylate 40(3) Hydroxyethyl acrylate 20(4) ethylacryloyloxyethyl phosphate .8______________________________________
The solution is adjusted to spray viscosity by dilution with the inert solvent mixture described in Example VII and sprayed onto a metal panel. After curing, the composition forms a hard, water resistant and abrasion resistant film.
EXAMPLE IX
A radiation polymerizable coating is prepared from the following materials in the manner hereinafter set forth;
Step 1______________________________________Preparation of Polymer Parts by Weight(1) Methyl methacrylate 290(2) Methacrylic acid 10(3) t-butylperoctoate 1.5(4) Toluene 300(5) 10% t-butylperoctoate in toluene 10______________________________________
A mixture of items 1 and 2 is added dropwise over a two hour period to a reaction flask (equipped with a condenser, thermometer, agitator, and dropping funnel) containing item 3 maintained at reflux. The mixture is refluxed two to three additional hours; item 4 is charged to the flask at the end of the first hour. The polymer so obtained has a number average molecular weight of about 13,000.
Step 2______________________________________Formulation of Coating Parts by Weight(1) Polymer from Step 1 27(2) Neopentylglycol diacrylate 35(3) 2-ethylhexyl acrylate 38(4) 2-methacryloyloxyethyl phosphate .5______________________________________
The polymer solution from Step 1 is mixed with monomers to give the ratios of polymer to monomer indicated above. The resulting solution is reduced to spray viscosity (about 15 seconds, Ford cup No. 4) using a mixture of butyl acetate, toluene, ethyl acetate and isopropanol in proportion by weight 4:4:1:1.
The film forming composition so obtained is applied to a plastic substrate bearing vapor deposited aluminum and cured according to the procedures of Example I. The coating is essentially unaffected by 240 hour exposure to water at 90.degree. F. No failure is observed in 240 hour 5% salt spray.
EXAMPLE X
The procedures of Example IX are followed except that:
(1) a polymer having a molecular weight (M.sub.n) of about 7,000 is prepared in accordance with Step 1 using
______________________________________ Parts by WeightMethyl methacrylate 200t-butylperoctoate 3Toluene 3007% t-butylperoctoate in toluene 10______________________________________
(2) 1.0 parts by weight of 2-methacryloyloxyethyl phosphate is admixed with the polymer and other components to form the coating composition. The composition is applied to and cured in situ on a glass substrate coated with vacuum deposited aluminum to produce a hard, corrosion and abrasion resistant surface.
EXAMPLE XI
The procedures of Example X are repeated with the difference that the coating formulation comprises: 70 parts by weight polymer; 30 parts by weight neopentylglycol diacrylate; and 2 parts by weight alpha, 2,2 diethoxyacetophenone. This formulation is reduced to spray viscosity (about 15 seconds Ford cup No. 4) using a 1:1 mixture of tolyene and butylacetate.
The film forming composition so obtained is applied to a substrate and cured thereon by exposure for 3 minutes in a nitrogen atmosphere to radiation from a low pressure mercury lamp (intensity about 4 .times. 10.sup.16 photons sec .sup..sup.-1 cm.sup..sup.-2, major UV peak at 2537 angstroms) at a distance of 1 inch. The cured coating displays adhesion to aluminum and solvent and water resistance essentially equivalent to those of a comparable electron beam cured coating.
EXAMPLE XII
The procedure of Example XI is repeated with the difference that the coating formulation is reduced to spray viscosity, sprayed on a plastic substrate coated with vacuum deposited aluminum and cured by exposure to UV light. The cured coating displays excellent water and solvent resistance and adhesion to the vacuum deposited metal surface.
EXAMPLE XIII
The procedure of Example X is repeated with the difference that the monomer used in preparation of the polymer comprises 194 parts by weight methyl methacrylate and 6 parts by weight acrylic acid. The coating composition so formed is reduced to spray viscosity (about 15 seconds Ford cup No. 4) using a 1:1 mixture of toluene and butylacetate, and sprayed on both plastic substrated coated with vacuum deposited aluminum and solid aluminum substrates. The coating formulation so applied is cured by exposure for 3 minutes in a nitrogen atmosphere to radiation from a low pressure mercury vapor lamp as discussed in Example XI. The cured coating displays excellent solvent and water resistance essentially equivalent to those of a comparable electron beam cured coating.
EXAMPLE XIV
The procedures of Examples XI and XII are repeated with the sole difference that the photoinitiator used is 2-ethylhexyl-2 cyano-3,3 diphenylacrylate. Essentially equivalent results are obtained.
EXAMPLE XV
The procedures of Example XIII are repeated with the sole difference that 3 weight percent of benzophenone is incorporated as the photoinitiator in lieu of the 2,2 diethoxyacetophenone. Essentially equivalent results are obtained.
EXAMPLE XVI
Commercially available materials may be used for the polymer. Film forming solutions are prepared from Acryloid A21LV and Acryloid B48N as set forth hereinafter. Acryloid A21LV is marketed by Rohm & Haas Co. and is described as a methyl methacrylate polymer having Tg=105.degree. C; it is supplied as a 30% by weight solution in a mixture of toluene, methyl ethyl ketone, and butanol (in proportion by weight 50:40:10) at a Brookfield viscosity of 210-280 cps at 25.degree. C. The number average molecular weight is about 13,000. Acryloid B48N is marketed by Rohm & Haas Co. and is described as a methyl methacrylate copolymer having Tg=50.degree. C; it is supplied as a 45% by weight solution in toluene at Brookfield viscosity of 6,000 to 10,000 at 25.degree. C. The number average molecular weight is about 15,000. Phosmor M is a product of Yushi Seihin K. K. a subsidiary of Nihon Oil & Fat Co., Ltd. and is primarily 2-methacryloyloxyethylphosphate.
Coating compositions A, B, C, D and E are prepared as follows:
______________________________________ Parts by Weight A B C D E______________________________________Acryloid B48N (solids basis) 35 0 0 15 0Acryloid A21LV (solids basis) 0 23 23 0 652-ethylhexyl acrylate 30 40 40 35 5Neopentylglycol diacrylate 35 37 0 0 01,6-hexanediol diacrylate 0 0 37 0 30Trimethylolpropane triacrylate 0 0 0 50 0Phosmor M .5 1.4 .7 2.1 .3______________________________________
All were reduced to spray viscosity using an inert solvent mixture of toluene, methyl ethyl ketone, butyl acetate and isopropanol. The solutions are than sprayed on substrates bearing vacuum deposited aluminum surfaces and cured thereon using an electron beam to give a total radiation dose of 9 Mrads (voltage 275 KV., current 40 ma). All the cured coatings so obtained displayed excellent adhesion to the substrates and good solvent and water resistance. Coatings formed from compositions A, C and E also display excellent corrosion protection when immersed in a 5% aqueous solution of sodium chloride for a period of 30 days. The coatings formed from compositions B and D, on the other hand, exhibited poor water resistance. The films formed from D became hazy under the above test conditions as well as under 240 hours immersion in water at 90.degree. F.
EXAMPLE XVII
The coatings of Example XVI are compared with a coating from which the thermoplastic polymer is omitted. A mixture of 50 parts by weight 2-ethylhexyl acrylate and 50 parts by weight 1,6-hexanediol diacrylate was prepared, applied to a substrate and cured under the conditions specified in Example XI. The coating obtained displayed very poor adhesion, especially to polymeric substrates.
EXAMPLE XVIII
A plural coated article including a vacuum deposited metal layer is prepared as follows.
A. Preparation and Application of Base Coat
______________________________________ Parts by Weight(1) Acryloid B82 50(2) Pentaerythritol triacrylate 100______________________________________
Components (1) and (2) are mixed in the indicated proportions by weight, reduced to spray viscosity (13 sec. Ford Cup No. 4) using an inert solvent mixture of toluene, methyl ethyl ketone, butyl acetate and isopropanol, applied to an injection molded ABS (acrylonitrile-butadiene-styrene copolymer) plastic substrate, and cured thereon by exposure to an electron beam in an inert atmosphere at 280 KV, 40 ma for a total dose of 8 Mrads.
B. Application of the Metal Layer
A layer of type 430 stainless steel is deposited on the base coated substrate by a conventional vacuum deposition technique employing electron beam heating of the evaporant.
C. Preparation and Application of Top Coat
______________________________________ Parts by Weight(1) Acryloid A21LV 40(2) neopentylglycol diacrylate 30(3) 2-ethyl hexyl acrylate 30(4) 2-methacryloyloxyethyl phosphate 0.5______________________________________
The listed components are mixed in the indicated proportions by weight, reduced to spray viscosity with an inert solvent mixture of toluene and methyl ethyl ketone, applied to the metallized substrate, and cured by exposure to an electron beam at 280 KV and 40 ma for a total dose of 8 Mrad.
EXAMPLE XIX
The procedures of Example XVIII are repeated with the difference that the top coat is replaced successively by those specified in Examples XXV - XXVII which follow with essentially equivalent results.
EXAMPLE XX
An electron polymerizable coating is formulated in the manner set forth in Example IX using the following materials:
______________________________________ Parts by Weight(1) Polymer from Step 1, Example IX 30(2) Trimethylolpropane triacrylate 20(3) 2-ethylhexyl acrylate 50(4) 2-acryloyloxyethylphosphate .75______________________________________
The coating compositon is sprayed on a plastic substrate bearing a coating of vapor deposited stainless steel and cured by electron beam irradiation. The resultant film exhibits excellent adhesion as well as good solvent resistance and corrosion resistance.
EXAMPLE XXI
An electron polymerizable coating is formulated in the manner set forth in Example IX using the following materials:
______________________________________ Parts by Weight(1) Polymer from Step 1, Example IX 30(2) Pentaerythritol tetraacrylate 20(3) 2-ethylhexyl acrylate 50(4) ethylmethacryloyloxyethyl phosphate .3______________________________________
The coating composition is sprayed on a glass substrate bearing a coating of vacuum deposited aluminum and cured by an electron beam. The resultant film exhibits outstanding solvent and corrosion resistance.
EXAMPLE XXII
Commercially available resins of high molecular weight may be used in the preparation of low solids content coatings. Film forming solutions are prepared from Elvacite 2009 and Elvacite 2041 as set forth hereinafter. Elvacite 2009 and Elvacite 2041 are marketed by E. I. Du Pont de Nemours & Co., Inc. Electrochemicals Department and are described as methyl methacrylate polymers of medium and very high molecular weight, respectively. The number average molecular weights of the resins used for the present work is 57,000 (Elvacite 2009) and 240,000 (Elvacite 2041); the corresponding weight average molecular weights are 106,000 and 540,000.
______________________________________ Parts by Weight A B______________________________________Elvacite 2009 21.5 --Elvacite 2041 -- 232-ethylhexyl acrylate 44 46Neopentylglycol acrylate 34 31Methacryloyloxyethyl phosphate 0.5 0.5______________________________________ Formulation A is reduced to spray viscosity using a 40/40/20 mixture of methylethylketone, toluene, and ethyl acetate, while formation B is reduced to spray viscosity with a 50/50 mixture of toluene and methylethyl ketone. The coating formulations obtained are sprayed upon plastic substrates previously decorated by vacuum deposition of aluminum, and are cured thereon. The composite coatings so obtained display exceptional mar resistance and corrosion resistance.
EXAMPLE XXIII
The procedure of Example I is repeated with the exception that 2.5 parts of 2-methacryloxyethyl phosphate are employed. The cured films adhere well when dry but develop an unacceptable bluish haze and soften upon exposure to water.
EXAMPLE XXIV
A plural coated article including a vacuum deposited metal layer is prepared as follows.
A. Preparation and Application of Base Coat
Step 1______________________________________Preparation of Polymeric Intermediate Mole Percent Mole Percent______________________________________(1) Adipic Acid 24 28(2) Maleic Anhydride 8 5.6(3) Neopentyl glycol 38 31.1(4) Hexamethylene diisocyanate 16 22.1(5) 2-hydroxyethylacrylate 14 13.2______________________________________
Components (1), (2) and (3) are charged to a reaction vessel equipped in the usual manner for polyester synthesis (i.e., so that water can be removed during the course of the reaction) and heated gradually to 230.degree. C. When an acid value of less than 16 is obtained (average reactant time 16 hours), the mixture is cooled to 150.degree. C and 0.04 weight percent hydroquinone is added. The mixture is further cooled to below 100.degree. C and reduced to 70% solids with butyl acrylate.
Component (4) is added at room temperature and the mixture is heated at 60.degree.-70.degree. C until an isocyanate level of 5% is obtained.
Component (5) is added at 70.degree. C and the mixture heated at 80.degree.-100.degree. C until the isocyanate is completely reacted. The mixture is reduced to 60% solids with equal parts of 2-hydroxyethylacrylate and butylacrylate.
Step 2______________________________________Preparation of Coating Formulation Parts by Weight(1) Resin solution from I 60(2) 2-hydroxyethylacrylate 10(3) Hydroxyethylacrylate 20(4) Methylmethacrylate 40______________________________________
The listed components are mixed in indicated proportions by weight, sprayed on a plastic substrate and cured with an electron beam in a nitrogen atmosphere at 280 KV, 40 ma for a total dose of 10 Mrads.
B. Application of Metal Layer
A layer of type 430 stainless steel is deposited on the base coat by a conventional vacuum deposition technique employing electron beam heating of the evaporant.
C. Preparation and Application of Top Coat
Step 1. Preparation of Resin
An electron polymerizable coating is prepared from the following materials in the manner hereinafter set forth:
______________________________________ Parts by Weight(1) Methyl methacrylate 300(2) t-butylperoctoate 1.5(3) Toluene 300(4) 10% t-butylperoctoate in toluene 10______________________________________
A mixture of items 1 and 2 is added dropwise over a 2 hour period to a reaction flask (equipped with a condenser, thermometer, agitator, and dropping funnel) containing item 3 maintained at reflux. The mixture is refluxed two to three additional hours; item 4 is charged to the flask at the end of the first hour. The polymer so obtained has a number average molecular weight of about 14,400.
Step 2______________________________________Preparation of Coating Parts by Weight A B______________________________________(1) Polymer from Step 1 27 50(2) Neopentylglycol diacrylate 35 20(3) 2-ethylhexyl acrylate 38 24(4) Phosmor M* .3 .3______________________________________ *Phosmor M is a product of Yushi Seihin K.K., a subsidiary of Nihon Oil & Fat Co., Ltd. and is primarily 2-methacryloyloxyethyl phosphate.
The film forming top coat so obtained is applied by flow coating on the surface of the article bearing the vacuum deposited metal and cured by electron beam irradiation at 280 KV, 40ma for a total dose of 10 Mrads.
The resultant vapor metallized article passes crosshatch adhesion tests, can withstand a minimum of 50 rubs with a cloth soaked in methyl ethyl ketone. Also, the plural coated article is unaffected by immersion in water at 90.degree. F for 240 hours and 10 day immersion in a 5% aqueous sodium chloride solution.
EXAMPLE XXV
The procedures of Example XXIV are followed with the difference that:
1. The polymer solution of (C) Step 1 is prepared using:
______________________________________ Parts by Weight(a) Methyl methacrylate 200(b) t-butylperoctoate 3(c) Toluene 300(d) 7% t-butylperoctoate in toluene 10______________________________________
(The polymer obtained has a number average molecular weight of about 7,000); and
2. the coating of (C) Step 2 contains .3 parts of di(2-methacryloxyoxyethyl) phosphate instead of Phosmor M. The resultant vapor metallized article passes cross-hatch adhesion tests and can withstand a minimum of 50 rubs with a cloth soaked in methyl ethyl ketone. Also, the plural coated article is unaffected by immersion in water at 90.degree. F for 240 hours and 10 day immersion in a 5% aqueous sodium chloride solution.
EXAMPLE XXVI
The procedure of Example XXIV is repeated except that:
______________________________________ Parts by Weight(1) Methyl methacrylate 194(2) Acrylic acid 6(3) t-butylperoctoate 1(4) Toluol 300(5) 10% t-butylperoctoate in Toluol 10______________________________________
(The polymer obtained has a number average molecular weight of about 14,000); and (2) .6 parts of 2-acryloyloxyethyl phosphate are used as the phosphate additive in (C) Step 2. The resultant vapor metallized article passes cross-hatch adhesion tests, can withstand a minimum of 50 rubs with a cloth soaked in methyl ethyl ketone, is unaffected by immersion in water at 90.degree. F for 240 hours and is unaffected by 10 days immersion in a 5% aqueous sodium chloride solution.
EXAMPLE XXVII
The procedure of Example XXIV is repeated except that in (B) a layer of aluminum is deposited by employing a tungsten filament to heat the evaporant; and the polymer of (C) Step 1 is prepared by using:
______________________________________ Parts by Weight(1) Methyl methacrylate 150(2) Butyl methacrylate 45(3) Acrylic acid 5(4) t-butyl peroctoate 1(5) Toluene 300(6) 10% t-butylperoctoate in toluol 10______________________________________
The polymer obtained has a number average molecular weight of about 14,000. The resultant vacuum metallized article passes cross-hatch adhesion tests, can withstand a minimum of 50 rubs with a cloth soaked in methyl ethyl ketone, is unaffected by immersion in water at 90.degree. F for 240 hours and is unaffected by 10 days immersion in a 5% aqueous sodium chloride solution.
EXAMPLE XXVIII
The procedure of Example XXIV is repeated with two exceptions. First the base coat composition is prepared from commercial electron beam polymerizable resins as follows:
______________________________________ Parts by Weight A B______________________________________(1) RD2107-30* 40 --(2) RD2278-58* -- 60(3) hydroxyethylacrylate 20 20(4) methyl methacrylate 50 40______________________________________ *Both of these resins are unsaturated polyurethanes manufactured by Hughson Chemical Company of Erie, Pennsylvania. (1) is supplied as a solution of 80% polymer, 20% 2-ethylhexyl acrylate; and (2) is supplied a a solution of 70% polymer, 15% methyl methacrylate, and 15% 2-ethylhexyl acrylate. Second, .7 parts of di(2-acryloyloxyethyl) phosphate are employed as the organophosphate ester component. The coated article so obtained passes cross-hatch adhesion tests and can withstand a minimum of 50 rubs with a cloth soaked in methyl ethyl ketone. The surface coating does not soften or change color, and the underlying material is similarly unaffected by 240 hours exposure to water at 90.degree. F. No failure is observed in 240 hours immersion in a 5% aqueous sodium chloride solution.
EXAMPLE XXIX
The procedure of Example XXIV is followed with the exception that the vapor deposited metal is aluminum and the top coat is prepared using commercially available resins as follows:
______________________________________ Parts by Weight A B C D E______________________________________Acryloid B48N (solid basis) 35 0 0 15 0Acryloid A21LV (solid basis) 0 23 23 0 652-ethylhexyl acrylate 30 40 40 35 5Neopentylglycol diacrylate 35 37 0 0 01,6-hexanediol diacrylate 0 0 37 0 30trimethylolpropane triacrylate 0 0 0 50 02-methacryloyloxyethylphosphate .1 .5 .8 .4 .3______________________________________
Acryloid B48N and Acryloid A21LV are commercially available materials. Acryloid A21LV is marketed by Rohm & Haas Co. and is described as a methyl methacrylate polymer having a T.sub.g =105.degree. C.; it is supplied as a 30% by weight solution in a mixture of toluene, methyl ethyl ketone, and butanol (in proportion by weight 50:40:10) at a Brookfield viscosity of 210-280 cps. at 25.degree. C. The number average molecular weight is about 13,000. Acryloid B48N is marketed by Rohm & Haas Co. and is described as a methyl methacrylate copolymer having a T.sub.g =50.degree. C; it is supplied as a 45% by weight solution in toluene at a Brookfield viscosity of 6000 to 10,000 at 25.degree. C. The number average molecular weight is about 15,000.
All of the above coatings are reduced to spray viscosity using an inert solvent mixture of toluene, methylethyl ketone, butylacetate and isopropanol and are spray coated on the vacuum metallized surfaces. The coating is then cured by electron beam to give a total radiation dose of 9 Mrads (voltage 275 KV, current 40ma).
The resultant coated articles pass cross-hatch adhesion tests and can withstand 50 rubs with a cloth soaked in methyl ethyl ketone. The surface coating does not soften or change color, and the underlying metal is similarly unaffected by 240 hours exposure to water at 90.degree. F. No failure is observed in 240 hours immersion in a 5% aqueous chloride solution.
EXAMPLE XXX
A plural coated article including a vacuum deposited metal layer is prepared as follows: (A) A commercially available base coat lacquer Red Spot SM 1817 sold by Red Spot Paint and Varnish Company and including a urealkyd type polymer is applied to a glass substrate and cured by heating for 90 minutes at 170.degree. F. (B) An aluminum layer is deposited on the base coat by a conventional vacuum deposition technique. (C) A top coat formulation having the following composition is prepared:
______________________________________ Parts by Weight(1) Acryloid A21LV (solid basis) 32(2) 2-ethylhexyl acrylate 38(3) neopentylglycol diacrylate 30(4) ethylmethacryloyloxyethyl phosphate .4______________________________________
The coating is reduced to spray viscosity using a 40:40:10 mixture of butyl acetate, toluene, methlethyl ketone and isopropanol, sprayed onto the vacuum metallized substrate, and then cured by an electron beam at a total dose of 9 Mrad.
The resultant vacuum metallized article exhibits a taped cross hatch rating for adhesion to aluminum of 9 (a rating of zero corresponding to complete catastrophic removal of a coating and 10 corresponding to no removal). The coated article also can withstand a 30 to 50 rubs with a cloth soaked in methyl ethyl ketone and is unaffected by either 240 hour immersions in water at 90.degree. F or 10 day immersion in a 5% aqueous sodium chloride solution.
EXAMPLE XXXI
The procedure of Example XXX is repeated except that: (1) the lacquer base coat employed is a melamine-formaldehyde resin; and (2) the top coat formulation is:
______________________________________ Parts by Weight(1) Acryloid B48N (solid basis) 30(2) 2-ethylhexyl acrylate 37(3) neopentylglycol diacrylate 33(4) ethylacryloyloxyethyl phosphate .6______________________________________
The resultant vacuum metallized article exhibits a taped cross-hatch rating for adhesion to aluminum of 8. The article can withstand 30 to 50 rubs with a cloth soaked in methyl ethyl ketone and is unaffected by either 240 hour immersion in water at 90.degree. F or 10 day immersion in a 5% aqueous sodium chloride solution.
EXAMPLE XXXII
A plural coated article including a vacuum deposited metal layer is prepared as follows: (A) A base coat having the following formulation is prepared:
______________________________________ Parts by Weight(1) Elvacite 6011* (40% solids in a 30/70 mixture of acetone and toluene) 40.0(2) trimethylolpropane triacrylate 24.0(3) hydroxypropylacrylate 8.0(4) 2-ethylhexylacrylate 16.0(5) methyl ethyl ketone 12.0______________________________________ *Elvacite 6011 is a methylmethacrylate polymer manufactured by Dupont. Th inherent viscosity of a solution of .25 grams polymer in 50 ml chloroform measured at 25.degree. C in a No. 50 Cannon-Fenske Viscometer is .34.
The above materials are mixed and the formulation reduced to spray viscosity (No. 1 Zahn Cup, 40 secs) with a 1:1 mixture of toluene and butyl acetate. The formulation is then sprayed on a plastic substrate and cured by exposure to electron beam irradiation as in previous examples. B. An antimony layer is deposited on the base coat by conventional vacuum deposition technique using a tungsten filament to heat the evaporant. C. A top coat is prepared from the following materials:
______________________________________ Parts by Weight(1) Acryloid A21LV (30% non solids) 50.0(2) 1,6 hexane diol diacrylate 24.0(3) 2-ethylhexyl acrylate 26.0(4) Phosmor M 0.2______________________________________
These materials are mixed, reduced to spray viscosity with 1:1 toluene and butyl acetate, sprayed on the vacuum metallized surface and cured by electron beam irradiation (9 Mrad dose).
The plural coated article passes cross-hatch tape adhesion tests, and resists in excess of 50 rubs with a cloth soaked in methyl ethyl ketone. Also, the coated article resists exposure to water at 90.degree. F and a 5% aqueous solution of sodium chloride for 240 hours.
EXAMPLE XXXIII
A plural coated article including a vacuum deposited metal layer is prepared as follows: A. A base coat having the following formulation is prepared:
______________________________________ Parts by Weight(1) Elvacite 6012* 40.0(2) trimethylolpropane triacrylate 24.0(3) hydroxypropylacrylate 8.0(4) 2-ethylhexylacrylate 16.0(5) methyl ethyl ketone 12.0______________________________________ *Elvacite 6012 is a methylmethacrylate polymer manufactured by Dupont. Th inherent viscosity of a solution of .25 grams polymer is 50 ml chloroform measured at 25.degree. C in a No. 50 Cannon-Fenske viscometer is .38.
The above materials are mixed and reduced to spray viscosity (No. 1 Zahn Cup, 40 Secs.) with a 1:1 mixture of toluene and butyl acetate. The formulation is sprayed on a steel substrate and cured by exposure to electron beam irradiation (9 Mrad dose) as in previous examples. B. An aluminum layer is deposited on the base coat by conventional vacuum deposition. C. A top coat is prepared in accordance with the following: (1) A polymer is prepared as follows:
______________________________________ Parts by Weight(1) Methyl methacrylate 300(2) t-butylperoctoate 1.5(3) Toluene 300(4) 10% t-butylperoctoate in toluene 10______________________________________
A mixture of items 1 and 2 is added dropwise over a 2 hour period to a reaction flask (equipped with a condenser, thermometer, agitator and dropping funnel) containing item 3 maintained at reflux. The mixture is refluxed two to three additional hours; item 4 is charged to the flask at the end of the first hour. The polymer so obtained has a number average molecular weight of about 13,000. (2) 50 parts by weight of the polymer prepared in (1) is combined with 24.0 parts of hexanediol diacrylate, 26.0 parts of 2-ethyl hexyl acrylate; and 0.2 parts of 2-methacryloylethyloxy phosphate.
These materials are mixed, reduced to spray viscosity with 1:1 toluene and butyl acetate, sprayed on the vacuum metallized surface and cured by electron beam irradiation as in previous examples.
The plural coated article passes cross-hatch tape adhesion tests, and resists in excess 50 rubs with a cloth soaked in methyl ethyl ketone. The article is also not adversely affected by exposure to water at 90.degree. F and a 5% aqueous solution of sodium chloride for 240 hours.
EXAMPLE XXXIV
A plural coated article including a vacuum deposited metal layer is prepared as follows: (A) The same base coat as employed in Example XXXIII is flow coated on a plastic substrate and cured by electron beam irradiation. (B) An antimony layer is deposited on the base coat by conventional vacuum deposition. (C) A top coat is prepared in accordance with the following: (1) a polymer is prepared as follows:
______________________________________ Parts by Weight(1) Methyl methacrylate 200(2) t-butylperoctoate 3.0(3) Toluene 300(4) 10% t-butylperoctoate in toluene 10______________________________________
A mixture of items 1 and 2 is added dropwise over a 2 hour period to a reaction flask (equipped with a condenser thermometer, agitator, and dropping funnel) containing item 3 maintained at reflux. The mixture is refluxed two to three additional hours; item 4 is charged to the flask at the end of the first hour. The polymer so obtained has a number average molecular weight of about 7,800. (2) 50 parts by weight of the polymer prepared in (1) is combined with 24.0 parts of 1,6 hexane dioldiacrylate, 26.0 parts of 2-ethylhexyl acrylate and 0.2 parts of Phosmor M.
These materials are mixed, reduced to spray viscosity with 1:1 toluene and butyl acetate, spray on the metallized surface and cured by electron beam irradiation.
The plural coated article passes cross-hatch adhesion tests, and resists in excess of 60 rubs with a cloth soaked in methyl ethyl ketone. Exposure for 10 days to either water at 90.degree. F or 5% aqueous salt spray produces no deterious effects on the composite.
EXAMPLE XXXV
A plural coated article including a vacuum deposited metal layer is prepared as follows: A. A base coat having the following formulation is prepared:
______________________________________ Parts by Weight(1) Acryloid B-44 (40%)* 38.5(2) Trimethyolpropanetriacrylate 38.5(3) Hydroxypropylacrylate 7.7(4) 2 ethyl hexyl acrylate 15.3______________________________________ *Acryloid B-44 is a methyl methacrylate copolymer having a T.sub.g of 60.degree. C and has a Brookfield viscosity at 25.degree. C of 855 to 1700. It is supplied as a 40% solution in a 95/5 toluene/methyl cellosolv mix by Rohm & Haas Co.
The above materials are mixed and reduced to spray viscosity (No. 1 Zahn Cup, 40 Secs.) with a 1:1 mixture of toluene and butyl acetate.
The formulation is applied to a glass substrate and cured by exposure to electron beam irradiation (9 Mrad dose) as in previous examples. B. An aluminum layer is deposited on the base coat by conventional vacuum deposition. C. The same top coat as employed in Example XXXIII, except for the use of 0.4 parts of ethylmethacryloyloxyethyl phosphate as the organophosphate additive, is sprayed on the vacuum deposited metal and cured by electron beam irradiation.
The plural coated article passes the cross-hatch adhesion test as well as the water and aqueous salt solution exposure tests at 240 hours and resists over 50 rubs with a cloth soaked in methyl ethyl ketone.
EXAMPLE XXXVI
A plural coated article including a vacuum deposited metal layer is prepared as follows:
A. A base coat having the following formulation is prepared:
______________________________________ Parts by Weight(1) Acryloid B-44 57.0(2) trimethylolpropane triacrylate 14.3(3) neopentylglycoldiacrylate 9.5(4) 2-ethylhexyl acrylate 19.2______________________________________
The above materials are mixed and the formulation reduced to spray viscosity (No. 1 Zahn Cup, 40 secs.) with a mixture of 1:1 toluene and butyl acetate. The formulation is then sprayed on a plastic substrate and cured by electron beam irradiation (9 Mrad dose). B. An aluminum layer is deposited on the base coat by conventional vacuum deposition technique. C. A top coat, which is the same as that applied in Example XXXII except that .3 parts of ethylmethacryloyloxyethyl phosphate are substituted for the Phosmor M, is sprayed on the vacuum metallized surface and cured by electron beam irradiation (9 Mrad dose).
The plural coated article passes the cross-hatch adhesion test as well as the water and aqueous salt solution exposure tests at 240 hours and resists in excess of 50 rubs with a cloth soaked in methyl ethyl ketone.
EXAMPLE XXXVII
A plural coated article including a vacuum deposited metal layer is prepared as follows: A. A base coat having the same formulation as that of Example XXXVI is sprayed on a plastic substrate. B. An antimony layer is deposited on the base coat by conventional vacuum deposition. C. A top coat having the same formulation as that used in Example XXXIV except that .6 parts of methyl (2-methacryloyloxyethyl) phosphate is substituted for the Phosmor M is sprayed on the vacuum metallized surface and cured by electron beam irradiation (9 Mrad dose).
The resultant article withstands a minimum of 50 rubs with a methyl ethyl ketone soaked cloth as well as 240 hours exposure to water at 90.degree. F and 5% aqueous salt solution and also passes to cross-hatch tape adhesion test.
EXAMPLE XXXVIII
The procedure of Example XXXII are repeated except that 0.2 parts of Phosmor M are included in the base coat formulation. The plural coated articles are comparable to those of Example XXXII.
EXAMPLE XXXIX
The procedure of Example XXXIII is repeated with the exception that .4 parts of di(2-methacryloyloxyethyl) phosphate are included in the base coat formulation. The plural coated articles are comparable to those of Example XXXIII.
EXAMPLE XXXX
The procedure of Example XXXIV is repeated with the exception that 0.3 parts of (2-methacryloyloxyethyl) phosphate are included in the base coat. The plural coated articles are comparable to those of Example XXXIV.
EXAMPLE XXXXI
The procedure of Example XXXV is repeated with the exception that 0.6 parts of di(2-acryloyloxyethyl) phosphate are included in the base coat formulation. The plural coated articles are comparable to those of Example XXXV.
EXAMPLE XXXXII
The procedure of Example XXXVI is repeated with the exception that 0.8 parts of methyl acryloyloxyethyl phosphate are included in the base coat formulation. The plural coated articles are of comparable quality with those of Example XXXVI.
EXAMPLE XXXXIII
The procedure of Example XXXVII is repeated with the exception that 0.5 parts of ethyl acryloyloxyethyl phosphate are included in the base coat. The plural coated articles are comparable to those of Example XXXVII.
EXAMPLE XXXXIV
The procedures of Example X are followed with the difference that the coating formulation comprises 50 parts by weight polymer; 15 parts by weight neopentylglycol diacrylate; 10 parts by weight pentaerythritoltriacrylate; and 25 parts by weight of 2-ethylhexylacrylate.
EXAMPLE XXXXV
A plural coated article is prepared according to the procedures of Example XXXI with the difference that: the metal layer is deposited by sputtering an 80/20 chromium/iron alloy, and that the top coat formulation comprises 50 parts by weight polymer; 25 parts by weight 2-ethylhexylacrylate; 25 parts neopentylglycoldiacrylate; and 0.4 parts ethylmethacryloyloxyethyl phosphate.
It will be understood by those skilled in the art that modifications can be made in the foregoing example and within the scope of the invention as hereinbefore described and hereafter claimed.

Number	Name	Date
2934555	O'Brien et al.	Apr 1960
3030347	O'Brien et al.	Apr 1962
3637559	Pinkney	Jan 1972
3789051	Rees et al.	Jan 1974

Radiation polymerizable coating composition containing an unsaturated phosphoric ester

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