Method for forming in-mold coating multi-layer coating film

Patent metadata

Field	Value
Publication number	US-12485593-B2
Application number	US-202218690152-A
Country	US
Kind code	B2
Filing date	Oct 26, 2022
Priority date	Nov 10, 2021
Publication date	Dec 2, 2025
Grant date	Dec 2, 2025

Abstract

A method for forming an in-mold coating multi-layer coating film includes: forming an uncured first in-mold coating film by injecting a specific first in-mold coating material composition (X) between a molded base material and an inner wall of a first film coating mold; heating and curing the uncured first in-mold coating film; separating the first film coating mold from a surface of the cured first in-mold coating film; providing a gap between the surface of the cured first in-mold coating film and a second film coating mold; forming an uncured second in-mold coating film by injecting a specific second in-mold coating material composition (Y) between the surface of the cured first in-mold coating film and an inner wall of the second film coating mold; and heating and curing the uncured second in-mold coating film.

First claim

The invention claimed is:

1 . A method of forming an in-mold coated multi-layer coating film, the method comprising:
step (1): forming an uncured first in-mold coating film by injecting a first in-mold coating composition (X) between a molded base material and an inner wall of a first film-coating-mold, the first in-mold coating composition (X) containing a polymerizable unsaturated group-containing compound (x1) containing a polymerizable unsaturated group, and a compound (x2) containing a first reactive functional group other than a polymerizable unsaturated group and containing no polymerizable unsaturated group; step (2): heating the uncured first in-mold coating film to thereby cure the uncured first in-mold coating film and form a cured first in-mold coating film; step (3): separating the first film-coating-mold from a surface of the cured first in-mold coating film; step (4): providing a gap between the surface of the cured first in-mold coating film and a second film-coating-mold; step (5): forming an uncured second in-mold coating film by injecting a second in-mold coating composition (Y) between the surface of the cured first in-mold coating film and an inner wall of the second film-coating-mold, the second in-mold coating composition (Y) containing a compound (y1) containing a second reactive functional group capable of reacting with the first reactive functional group; and step (6): heating and curing the uncured second in-mold coating film, wherein the second film-coating-mold is the same as or different from the first film-coating-mold.

2 . The method of forming the in-mold coated multi-layer coating film according to claim 1 , wherein the polymerizable unsaturated group-containing compound (x1) contains a compound (x11) containing the polymerizable unsaturated group and the second reactive functional group.

3 . The method of forming the in-mold coated multi-layer coating film according to claim 1 , wherein the polymerizable unsaturated group-containing compound (x1) contains a vinyl aromatic compound (x12).

4 . The method of forming the in-mold coated multi-layer coating film according to claim 3 , wherein the polymerizable unsaturated group-containing compound (x1) contains the vinyl aromatic compound (x12) in an amount in a range from 20 to 91 mass % based on the content of the polymerizable unsaturated group-containing compound (x1).

5 . The method of forming the in-mold coated multi-layer coating film according to claim 1 , wherein the first reactive functional group contains an isocyanate group.

6 . The method of forming the in-mold coated multi-layer coating film according to claim 1 , wherein the second reactive functional group contains a hydroxyl group.

7 . The method of forming the in-mold coated multi-layer coating film according to claim 1 , wherein the second in-mold coating composition (Y) contains a compound (y2) containing the first reactive functional group and containing no polymerizable unsaturated group.

Assignees

• Kansai Paint Co Ltd

Inventors

• Komura Katsuto
• Nakaoka Haruka
• Kitamura Takashi

Classifications

• B29K2655/02

  ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers · CPC title

• B29K2623/12

  PP, i.e. polypropylene · CPC title

• B29K2025/06

  PS, i.e. polystyrene · CPC title

• B29L2007/00

  Flat articles, e.g. films or sheets (B29L2024/00 takes precedence) · CPC title

• B29K2101/10

  Thermosetting resins · CPC title