Polymer workpiece for flow coating

Patent metadata

Field	Value
Publication number	US-9802219-B2
Application number	US-201214351093-A
Country	US
Kind code	B2
Filing date	Nov 2, 2012
Priority date	Dec 14, 2011
Publication date	Oct 31, 2017
Grant date	Oct 31, 2017

Abstract

A polymer workpiece is described. The workpiece has an upper main surface, a lower main surface, an injection-mold separating surface and a flow attack edge surface. The flow attack edge surface is formed in the region between the injection-mold separating surface and the lower main surface as a planar surface with an angle α with respect to the injection-mold separating surface of 20° to 70°, and/or deviates by an amount a from 0.0 mm to 0.5 mm from the planar surface.

First claim

What is claimed is:

1. A polymer workpiece configured to reduce flow coating problems at an upper main surface of the polymer workpiece, the polymer workpiece comprising:
an upper main surface,
a lower main surface,
an injection-mold separating surface being an internal surface between the upper main surface and the lower main surface, and
a flow attack edge surface being an external surface between the upper main surface and the lower main surface, the flow attack edge surface comprising an upper attack surface and a lower attack surface,
wherein the upper attack surface is an entire region of the flow attack edge surface between the injection-mold separating surface and the upper main surface, and is formed as a convexly curved surface having an upper attack surface radius of curvature,
wherein the lower attack surface is an entire region of the flow attack edge surface between the injection-mold separating surface and the lower main surface, and is formed as a planar or convexly curved surface that deviates by an amount a from 0.0 mm to 0.5 mm from a planar surface that has an angle α relative to the injection-mold separating surface from 20° to 70°,
wherein the planar surface passes through i) a junction point of the upper attack surface and the injection-mold separating surface, and ii) a junction point of the lower main surface and the lower attack surface, and
wherein the upper attack surface radius of curvature, the amount a and the angle α are configured to guide a flow coating solution flooded onto the flow attack edge predominantly to the lower main surface to reduce flow coating problems at the upper main surface.

2. The workpiece according to claim 1 , wherein the angle α is from 30° to 60°.

3. The workpiece according to claim 1 , wherein the amount a is from 0.0 mm to 0.3 mm.

4. The workpiece according to claim 1 , wherein the lower attack surface is convexly curved having a radius of curvature larger than the upper attack surface radius of curvature, and a maximum of the amount a is preferably arranged in a center of the region.

5. The workpiece according to claim 1 , wherein the injection-mold separating surface is arranged at a distance from the upper main surface of 20% to 80% of a thickness d of the polymer workpiece adjacent the flow attack edge surface.

6. The workpiece according to claim 1 , containing at least polycarbonates (PC), polyethylene terephthalate (PET), and/or polymethyl methacrylate (PMMA).

7. The workpiece according to claim 1 , having a thickness d adjacent the flow attack edge surface from 1 mm to 10 mm.

8. The workpiece according to claim 1 , wherein the angle α is from 35° to 55°.

9. The workpiece according to claim 1 , wherein the amount a is from 0.0 mm to 0.2 mm.

10. The workpiece according to claim 1 , wherein the region of the flow attack edge surface is flat and a maximum of the amount a is 0.0 mm.

11. The workpiece according to claim 1 , wherein the injection-mold separating surface is arranged at a distance from the upper main surface of 33% to 67% of a thickness d of the polymer workpiece adjacent the flow attack edge surface.

12. The workpiece according to claim 1 , having a thickness d adjacent the flow attack edge surface from 2 mm to 7 mm.

13. The workpiece according to claim 4 , wherein the upper attack surface is more sharply curved than the lower attack surface.

14. A polymer workpiece configured to reduce flow coating problems at an upper main surface of the polymer workpiece, the polymer workpiece comprising:
an upper main surface,
a lower main surface,
an injection-mold separating surface including a surface region being an external surface between the upper main surface and the lower main surface, and
a flow attack edge surface comprising an upper attack surface, a lower attack surface, and the surface region of the injection-mold separating surface that joins the upper attack surface to the lower attack surface,
wherein the surface region of the injection-mold separating surface is a region of the flow attack edge surface facing the lower main surface running with a length from 0.005 mm to 0.1 mm along the injection-mold separating surface,
wherein the upper attack surface is an entire region of the flow attack edge surface between the injection-mold separating surface and the upper main surface that is formed as a convexly curved surface having an upper attack surface radius of curvature, and
wherein the upper attack surface radius of curvature and the length from 0.005 mm to 0.1 mm are configured to guide a flow coating solution flooded onto the flow attack edge predominantly to the lower main surface to reduce flow coating problems at the upper main surface.

15. The workpiece according to claim 14 , wherein the region of the flow attack edge surface has a length from 0.01 mm to 0.05 mm.

16. The workpiece according to claim 14 , wherein the lower attack surface is formed as a planar or convexly curved surface that deviates by an amount a from 0.0 mm to 0.5 mm from a planar surface that has an angle α relative to the injection-mold separating surface from 20° to 70°.

17. The workpiece according to claim 16 , wherein the angle α is from 30° to 60°.

18. The workpiece according to claim 16 , wherein the angle α is from 35° to 55°.

19. The workpiece according to claim 16 , wherein the amount a is from 0.0 mm to 0.3 mm.

20. The workpiece according to claim 16 , wherein the amount a is from 0.0 mm to 0.2 mm.

21. The workpiece according to claim 16 , wherein the amount a is from 0.0 mm to 0.0 mm.

22. A method for producing a coated polymer workpiece, comprising:
providing a polymer workpiece comprising an upper main surface, a lower main surface, an injection-mold separating surface between the upper main surface and the lower main surface that is an internal surface, and a flow attack edge surface comprising an upper attack surface and a lower attack surface,
wherein the upper attack surface is an entire region of the flow attack edge surface between the injection-mold separating surface and the upper main surface, and is formed as a convexly curved surface having an upper attack surface radius of curvature,
wherein the lower attack surface is an entire region of the flow attack edge surface between the injection-mold separating surface and the lower main surface, and is formed as a planar or convexly curved surface that deviates by an amount a from 0.0 mm to 0.5 mm from a planar surface that has an angle α relative to the injection-mold separating surface from 20° to 70°, and
wherein the planar surface passes through i) a junction point of the upper attack surface and the injection-mold separating surface, and ii) a junction point of the lower main surface and the lower attack surface, and
wherein the flow attack edge surface is an external surface between the upper main surface and the lower main surface,

arranging the polymer workpiece with the flow attack edge surface pointing upward at an angle α relative to horizontal from 25° to 85°, wherein the lower main surface is facing ground,
flooding the polymer workpiece from the flow attack edge surface onward with a coating solution, and
based on the flooding, the upper attack surface radius of curvature, the amount a, and the angle α, guiding the coating solution predominantly to the lower main surface and thereby reducing flow coating problems at the upper main surface.

23. The method according to claim 22 , wherein the workpie

Assignees

• Saint Gobain

Inventors

• Fleischmann Wolfgang
• Guldan Marcus
• Gueldner Dominic
• Lux Thomas

Classifications

• Y10T428/24488

  Differential nonuniformity at margin · CPC title

• B05D1/30 Primary

  performed by gravity only, i.e. flow coating · CPC title

• B05D7/02

  to macromolecular substances, e.g. rubber (treatment or coating of shaped articles made of macromolecular substances C08J7/00) · CPC title

• B05D2201/02

  Polymeric substrate · CPC title

• G02B1/10

  Optical coatings produced by application to, or surface treatment of, optical elements (G02B1/08 takes precedence) · CPC title