Process for applying automotive quality effect coatings to metal substrates

#The present invention relates to a process for applying a multi-component composite coating composition to a substrate.

#In the automotive industry as well as other general industrial manufacturing, there are ever-increasing demands for greater productivity, cost savings, and flexible and efficient production. Coupled with this are increasingly stringent requirements regarding environmental protection with respect to manufacturing operations and waste products. Such demands have to be met by modifying both raw materials and processing methods while still satisfying quality requirements expected by consumers.

#In the automotive industry, modular manufacturing systems are being considered in vehicle assembly plants, because of the time and cost savings that can be realized by integrating pre-fabricated and pre-coated body parts on an assembly line. For example, coil coating of sheet metal prior to fabrication into automotive body parts is being considered as a cost-saving manufacturing process. However, in today's market for automobiles with “glamour” coatings, including metallic colors and decorative visual effect pigments, achieving acceptable appearance properties by roll applying coatings to substrates such as on a continuous coil line can be difficult.

#FIG. 1 is a flow diagram depicting several embodiments of the process of the present invention.

#FIG. 2 is a plot of spectrophotometric measurements of L* values versus viewing angle for five color-plus-clear composite coatings applied by various application techniques.

#FIG. 3 is a plot of spectrophotometric measurements of “a values” versus viewing angle for the same five color-plus-clear composite coatings applied by various application techniques.

#Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients, reaction conditions and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

#Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

#Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of “1 to 10” is intended to include all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.