Formable film

Patent metadata

Field	Value
Publication number	US-10066122-B2
Application number	US-201514698422-A
Country	US
Kind code	B2
Filing date	Apr 28, 2015
Priority date	Oct 29, 2012
Publication date	Sep 4, 2018
Grant date	Sep 4, 2018

Abstract

A deformable film has a decorative surface featuring a completely matt appearance. For this purpose, the deformable film has a decorative surface provided with at least one coating comprising the following constituents: (a) an aqueous dispersion of a hydroxy-functional prepolymer, obtainable by conversion of at least one of the following components: (i) a component having hydroxyl groups, (ii) a polyester polyol having hydroxyl groups, (iii) a polyisocyanate having isocyanate groups, (iv) a compound having at least two groups reactive toward isocyanate groups and at least one group capable of anion formation, (v) water, where components (i) to (iii) and the ratio of components (i) to (iii) are selected such that an excess of hydroxyl groups is present relative to the isocyanate groups, and (b) nanoparticles having a number-average particle size of 1 to 1000 nm and (c) a crosslinker having at least two groups reactive toward hydroxyl groups.

First claim

What is claimed is:

1. A formable film with a decorative surface, the decorative surface having a coating comprising:
a) an aqueous dispersion of a hydroxy-functional prepolymer, obtained via reaction of at least the following components:
i) a component having hydroxy groups,
ii) a polyester polyol having hydroxy groups,
iii) a polyisocyanate having isocyanate groups,
iv) a compound which has at least two groups reactive toward isocyanate groups, and which has at least one group capable of anion formation, and
v) water,

where the components i) to iii) and the ratio of components i) to iii) are selected in such a way that the hydroxy-functional prepolymer has an excess of hydroxy groups;
b) nanoparticles with number-average particle size from 5 to 100 nm;
c) a crosslinking agent that has at least two groups reactive toward hydroxy groups; and,
d) at least one matting agent,
wherein the nanoparticles are inorganic oxides or carbonates,
wherein the nanoparticles have a specific surface area of from 100 m 2 /g to 1000 m 2 /g, and
wherein the decorative surface coating has a uniform mattness throughout the grain valleys and grain peaks.

2. The formable film with decorative surface as claimed in claim 1 , wherein the film is subjected to a forming process.

3. The formable film with decorative surface as claimed in claim 1 , wherein the film is a single-or multilayer film.

4. The formable film with decorative surface as claimed in claim 1 being provided in the interior of an automobile.

5. The formable film with decorative surface as claimed in claim 1 , wherein the component having a hydroxy group is a polycarbonate polyol.

6. The formable film with decorative surface as claimed in claim 5 , wherein the polycarbonate polyol is 1000 g/mol to 2200 g/mol weight average molecular weight and/or 600 Daltons to 3000 Daltons number-averaged molecular weight.

7. The formable film with decorative surface as claimed in claim 1 , wherein the content of volatile organic compounds (VOC) in the formable film is 13 μg/g of toluene equivalent or less.

8. A formable film with a decorative surface, the decorative surface having a coating comprising:
a) an aqueous dispersion of a hydroxy-functional prepolymer, obtained via reaction of at least the following components:
i) a component having hydroxy groups,
ii) a polyester polyol having hydroxy groups,
iii) a polyisocyanate having isocyanate groups,
iv) a compound which has at least two groups reactive toward isocyanate groups, and which has at least one group capable of anion formation, and
v) water,

where the components i) to iii) and the ratio of components i) to iii) are selected in such a way that the hydroxy-functional prepolymer has an excess of hydroxy groups;
b) nanoparticles with number-average particle size from 5 to 100 nm;
c) a crosslinking agent which has at least two groups reactive toward hydroxy groups; and,
d) at least one matting agent,
wherein the nanoparticles are inorganic oxides or carbonates,
wherein the nanoparticles have a specific surface area of from 100 m 2 /g to 1000 m 2 /g, and
wherein the hydroxy-functional prepolymer is concomitantly reacted with a polyoxyalkylene ether having at least one hydroxy or amino group.

9. The formable film of claim 1 , wherein the uniform mattness is maintained after thermoforming the formable film.

10. A thermoformed film comprising a decorative surface coating, wherein the decorative surface coating comprises:
a) an aqueous dispersion of a hydroxy-functional prepolymer, obtained via reaction of at least the following components:
i) a component having hydroxy groups,
ii) a polyester polyol having hydroxy groups,
iii) a polyisocyanate having isocyanate groups,
iv) a compound which has at least two groups reactive toward isocyanate groups, and which has at least one group capable of anion formation, and
v) water,

where the components i) to iii) and the ratio of components i) to iii) are selected in such a way that the hydroxy-functional prepolymer has an excess of hydroxy groups;
b) nanoparticles with number-average particle size from 5 to 100 nm;
c) a crosslinking agent which has at least two groups reactive toward hydroxy groups; and,
d) at least one matting agent,
wherein the decorative surface coating is embossed with a decorative grain comprising one or more grain valleys and/or grain peaks, and
wherein the decorative surface coating has a uniform mattness throughout the grain valleys and/or grain peaks.

11. An automobile interior surface comprising a thermoformed film, wherein the thermoformed film comprises a decorative surface comprising a coating, wherein the decorative surface coating comprises:
a) an aqueous dispersion of a hydroxy-functional prepolymer, obtained via reaction of at least the following components:
i) a component having hydroxy groups,
ii) a polyester polyol having hydroxy groups,
iii) a polyisocyanate having isocyanate groups,
iv) a compound which has at least two groups reactive toward isocyanate groups, and which has at least one group capable of anion formation, and
v) water,

where the components i) to iii) and the ratio of components i) to iii) are selected in such a way that the hydroxy-functional prepolymer has an excess of hydroxy groups;
b) nanoparticles with number-average particle size from 5 to 100 nm;
c) a crosslinking agent which has at least two groups reactive toward hydroxy groups; and,
d) at least one matting agent,
wherein the decorative surface coating is embossed with a decorative grain comprising one or more grain valleys and/or grain peaks, and
wherein the decorative surface coating has a uniform mattness throughout the grain valleys and/or grain peaks.

12. The automobile interior surface of claim 11 , wherein the interior surface is a dashboard or a seat-covering.

Assignees

• Benecke Kaliko Ag
• Bayer Materialscience Ag
• Covestro Deutschland Ag

Inventors

• Iben Dirk
• Koch Heino
• Reusch Stefan
• Gewiss Heinz Dietmar
• Melchiors Martin
• Klippert Uwe
• Schrinner Marc Claudius

Classifications

• C08J7/0427

  with only one layer of a composition containing a polymer binder (with more layers C08J7/042) · CPC title

• Y10T428/24802

  Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] · CPC title

• C08G18/6659

  with compounds of group C08G18/34 · CPC title

• C09D175/04

  Polyurethanes · CPC title

• C08G18/7831

  containing biuret groups · CPC title