Granted Patent B2

US 7,329,462 · App. 10/638,099 · Granted Feb 12, 2008

Abstract

Claims (41)

1. A reflective article, comprising:

a substrate comprising an amorphous thermoplastic resin having

a heat distortion temperature of at least about 140° C. measured at 66 pounds per square inch according to ASTM D648,

a density less than 1.7 grams per milliliter, and

an organic volatiles content less than 1,000 parts per million measured according to ASTM D4526;

wherein the amorphous thermoplastic resin is selected from polyetherimides, polyetherimide sulfones, polysulfones, polyethersulfones, polyphenylene ether sulfones, poly(arylene ether)s, polycarbonates, polyester carbonates, polyarylates, and mixtures thereof;

a reflective metal layer; wherein the reflective metal layer comprises a metal selected from aluminum, silver, gold, nickel, palladium, platinum, copper, and alloys thereof; wherein the reflective metal layer has a thickness of about 20 to about 1,000 nanometers;

a haze-prevention layer interposed between the substrate and the reflective metal layer, wherein the haze-prevention layer comprises a material having a volume resistivity of at least 1×10 −4 ohm-centimeters measured according to ASTM D257 at 25° C. and a tensile modulus of at least about 3×10 5 pounds per square inch measured according to ASTM D638 at 25° C.; wherein the haze-prevention layer comprises a plasma-polymerized organosilicone; and

a protective layer comprising the plasma decomposition product of an oxidant and a reactant gas selected from silanes, disilanes, and organosilicon compounds; wherein the reflective layer is interposed between the haze-prevention layer and the protective layer;

wherein the protective layer is in contact with the reflective metal layer;

wherein the reflective metal layer is in contact with the haze-prevention layer; and

wherein the haze-prevention layer is in contact with the substrate.

2. The reflective article of claim 1 , wherein the substrate is substantially free of inorganic filler.

3. The reflective article of claim 1 , wherein the substrate has a thickness of about 0.1 to about 20 millimeters.

4. The reflective article of claim 1 , wherein the reflective metal layer comprises aluminum.

5. The reflective article of claim 1 , wherein the organosilicone has the formula

wherein each occurrence of R is independently hydrogen, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 3 -C 6 alkenyl alkyl, or C 6 -C 18 aryl; n is 0 to 100; m is 1 to 100; and X is —O— or —NH—.

6. The reflective article of claim 1 , wherein the organosilicone is octamethyl(cyclotetrasiloxane), hexamethyl(cyclotrisiloxane), tetramethyldisiloxane, hexamethyldisiloxane, octamethyltrisiloxane, vinyltriethoxysilane, vinyltrimethoxysilane cyclotetra(methylvinylsiloxane), cyclotri(methylvinylsiloxane), hexamethyldisilazane, or a mixture thereof.

7. The reflective article of claim 1 , wherein the haze-prevention layer has a thickness of about 100 nanometers to about 100 micrometers.

8. The reflective article of claim 1 , wherein the protective layer has a percent transmittance of at least 90% measured according to ASTM D1003 at 25° C.

9. The reflective article of claim 1 , comprising a surface with a reflectivity of at least 80% measured according to ASTM D523.

10. The reflective article of claim 1 , wherein the article is an automotive headlight reflector.

11. A reflective article, consisting essentially of:

a substrate comprising an amorphous thermoplastic resin having

a heat distortion temperature of at least about 140° C. measured at 66 pounds per square inch according to ASTM D648,

a density less than 1.7 grams per milliliter, and

an organic volatiles content less than 1,000 parts per million measured according to ASTM D4526;

wherein the amorphous thermoplastic resin is selected from polyetherimides, polyetherimide sulfones, polysulfones, polyethersulfones, polyphenylene ether sulfones, poly(arylene ether)s, polycarbonates, polyester carbonates, polyarylates, and mixtures thereof

a reflective metal layer; wherein the reflective metal layer comprises a metal selected from aluminum, silver, gold, nickel, palladium, platinum, copper, and alloys thereof; wherein the reflective metal layer has a thickness of about 20 to about 1,000 nanometers;

a haze-prevention layer interposed between the substrate and the reflective metal layer, wherein the haze-prevention layer comprises a material having a volume resistivity of at least 1×10 −4 ohm-centimeters measured according to ASTM D257 at 25° C. and a tensile modulus of at least about 3×10 5 pounds per square inch measured according to ASTM D638 at 25° C.; wherein the haze-prevention layer comprises a plasma-polymerized organosilicone; and

a protective layer comprising the plasma decomposition product of an oxidant and a reactant gas selected from silanes, disilanes, and organosilicon compounds; wherein the reflective layer is interposed between the haze-prevention layer and the protective layer;

wherein the protective layer is in contact with the reflective metal layer;

wherein the reflective metal layer is in contact with the haze-prevention layer; and

wherein the haze-prevention layer is in contact with the substrate.

12. A method for preparing a reflective article, comprising:

applying a haze-prevention layer to a surface of a substrate;

wherein the haze-prevention layer comprises a material having a volume resistivity of at least 1×10 −4 ohm-centimeters measured according to ASTM D257 at 25° C. and a tensile modulus of at least about 3×10 5 pounds per square inch measured according to ASTM D638 at 25° C.; wherein the haze-prevention layer comprises a plasma-polymerized organosilicone; and

wherein the substrate comprises an amorphous thermoplastic resin having a heat distortion temperature of at least about 140° C. measured at 66 pounds per square inch according to ASTM D648, a density less than 1.7 grams per milliliter, and an organic volatiles content less than 1,000 parts per million measured according to ASTM D4526; wherein the amorphous thermoplastic resin is selected from polyetherimides, polyetherimide sulfones, polysulfones, polyethersulfones, polyphenylene ether sulfones, poly(arylene ether)s, polycarbonates, polyester carbonates, polyarylates, and mixtures thereof;

applying a reflective metal layer to a surface of the haze-prevention layer; wherein the reflective metal layer comprises a metal selected from aluminum, silver, gold, nickel, palladium, platinum, copper, and alloys thereof; wherein the reflective metal layer has a thickness of about 20 to about 1,000 nanometers; and

applying a protective layer to a surface of the reflective metal layer; wherein the protective layer comprises the plasma decomposition product of an oxidant and a reactant gas selected from silanes, disilanes, and organosilicon compounds; and wherein the reflective layer is interposed between the haze-prevention layer and the protective layer.

13. The method of claim 12 , wherein the protective layer has a percent transmiffance of at least 90% measured according to ASTM D1003.

Assignments (7)