Lighting system with reflective coating having cross-linked polymeric powder and a pigment
Methods are provided for forming a reflective coating by applying a precursor material onto the substrate; soft curing the precursor material at a first curing energy level; and thereafter, hard curing the precursor material at a second curing energy level having a higher amount of energy than the first curing energy level to form the reflective coating. Other methods are provided for forming a reflective coating a surface of a plastic substrate by heating the surface of the plastic substrate to a deposition temperature, applying a polymeric resin onto the heated surface, and crosslinking the polymeric resin to form the reflective coating. The polymeric resin can include a cross-linkable powder, a cross-linker, and a pigment, with the deposition temperature being about 10° C. or greater than the melting point of the cross-linkable binder. Lighting apparatus formed from such methods are also provided.
1. A lighting system, comprising:
a lamp;
a reflector positioned to reflect light emitted by the lamp, wherein the reflector comprises a plastic substrate; and
a reflective coating deposited directly on a light reflecting surface of the reflector, wherein the reflective coating comprises a cross-linked polymeric powder and a pigment;
wherein the reflective coating reflects at least about 95% of light in the visible spectrum, with a matte finish having a gloss of 1 or less at 60 degree incident angle as measured by ASTM test method D523-08 as published in June 2008.
2. The lighting system as in claim 1 , wherein the cross-linked polymeric powder is formed from a cross-linkable powder and a cross-linker.
3. The lighting system as in claim 1 , wherein the reflective coating has a coating thickness of about 50 μm to about 500 μm.
4. A lighting system, comprising:
a lamp;
a reflector positioned to reflect light emitted by the lamp, wherein the reflector comprises a glass or metal substrate; and
a reflective coating deposited on a light reflecting surface of the reflector, wherein the reflective coating comprises a cross-linked polymeric powder and a pigment;
wherein the reflective coating reflects at least about 95% of light in the visible spectrum, with a matte finish having a gloss of about 1 or less at 60 degree incident angle as measured by ASTM test method D523-08 as published in June 2008.
5. The lighting system as in claim 4 , wherein the cross-linked polymeric powder is formed from a cross-linkable powder and a cross-linker.
6. The lighting system as in claim 4 , wherein the cross-linked powder comprises a polyester resin, and the pigment comprises titanium dioxide.
7. The lighting system as in claim 5 , wherein the cross-linker comprises polyfunctional aziridines, epoxy resins, carbodiimide, oxazoline functional polymers, melamine-formaldehyde, urea formaldehyde, amine-epichlorohydrin, multi-functional isocyanates, or combinations thereof.
8. The lighting system as in claim 4 , wherein the reflective coating has a coating thickness of about 50 μm to about 500 μm.
9. A lighting system, comprising:
a lamp;
a reflector positioned to reflect light emitted by the lamp, wherein the reflector comprises a plastic, glass or metal substrate; and
a reflective coating having a matte finish deposited on a light reflecting surface of the reflector,
wherein the reflective coating comprises inorganic pigment particles and a cross-linked resin, the cross-linked resin inhibited from substantially covering the inorganic pigment particles; and
wherein the reflective coating having a matte finish reflects at least about 95% of light in the visible spectrum and has gloss of 1 or less at 60 degree incident angle as measured by ASTM test method D523-08 as published in June 2008.