Low Heat Build-Up UV-Cured Vacuum Coating System in Dark Colors
A weatherable, low heat build-up, UV-cured vacuum coating for PVC or other extruded plastic profiles comprising a dark-colored pigment system that is substantially IR transparent, an IR reflective substrate, and a vacuum coating system for same.
1 . A heat build-up resistant extrudate with a dark-colored vacuum coating, comprising:
an IR reflective substrate portion formed of a thermoplastic resin that is substantially reflective of solar infrared radiation,
a dark-colored vacuum coating that is formed of a UV-cured vacuum coating that is significantly transmissive of solar infrared radiation and that covers at least a portion of the reflective substrate, and
wherein the extrudate exhibits a predicted horizontal heat build-up under ASTM D4803 of less than about 58° Fahrenheit.
2 . The extrudate with a dark-colored vacuum coating of claim 1 , wherein,
the thermoplastic resin contains greater than about 8 parts Ti0 2 per hundred parts base resin.
3 . The extrudate with a dark-colored capstock of claim 2 , wherein the first thermoplastic resin contains between 8 and 11 parts Ti0 2 per hundred base resin.
4 . The extrudate with a dark-colored capstock of claim 1 , further comprising a base portion formed of a second thermoplastic resin, wherein,
the IR reflective substrate portion covers at least part of the surface of the base portion,
and the dark-colored capstock portion covers at least part of the surface of the IR reflective substrate portion.
5 . The extrudate with a dark-colored vacuum coating of claim 4 , wherein the second thermoplastic resin is a rigid, solid thermoplastic.
6 . The extrudate with a dark-colored vacuum coating of claim 4 , wherein the second thermoplastic resin is a rigid, foamed thermoplastic resin.
7 . The extrudate with a dark-colored vacuum coating of claim 4 , wherein the base portion is formed of a rigid, foamed thermoplastic resin and wood flour composite.
8 . The extrudate with a dark-colored vacuum coating of claim 4 , wherein the base portion is formed of a rigid, foamed thermoplastic resin and mineral filler composite.
9 . A heat build-up resistant extrudate with a dark-colored vacuum coating, comprising:
an IR reflective substrate portion formed of a first thermoplastic resin containing between about 8 and 11 parts Ti0 2 per hundred resin that is substantially reflective of solar infrared radiation,
a dark-colored vacuum coating that is significantly transmissive of solar infrared radiation and that covers at least a portion of the IR reflective substrate,
wherein the extrudate exhibits a predicted horizontal heat build-up under ASTM D4803 of less than about 52° Fahrenheit.
10 . The extrudate with a dark-colored vacuum coating of claim 9 , further comprising a base portion formed of a second thermoplastic resin, wherein,
the IR reflective substrate portion covers at least part of the a surface of the base portion, and the dark-colored vacuum coating covers at least part of the a surface of the IR reflective substrate portion.
11 . The extrudate with a dark-colored vacuum coating of claim 10 , wherein the second thermoplastic resin is a rigid, solid thermoplastic.
12 . The extrudate with a dark-colored vacuum coating of claim 10 , wherein the second thermoplastic resin is a rigid, foamed thermoplastic resin.
13 . The extrudate with a dark-colored vacuum coating of claim 10 , wherein the base portion is formed of a rigid, foamed thermoplastic resin and wood flour composite.
14 . A method of producing a low heat build-up extrudate with a dark-colored vacuum coating, comprising:
coating a portion of a surface of an IR reflective substrate, formed of a first thermoplastic resin that is substantially reflective of solar infrared radiation, with a UV-cured vacuum coating using a vacuum coating gate and mask apparatus, where the vacuum coating gate and mask apparatus is supplied by a vacuum pump and supply apparatus, and
curing the vacuum coating in a primary UV oven.
15 . The method of claim 14 further comprising the step of further curing the vacuum coating in a secondary UV oven.
16 . The method of claim 15 , where the primary UV oven uses gallium UV lamps.
17 . The method of claim 15 , where the secondary UV oven uses mercury UV lamps
18 . (canceled)