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(12) United States Patent (10) Patent No.: US 7.404,987 B2 Karunaratne Et Al

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(12) United States Patent (10) Patent No.: US 7.404,987 B2 Karunaratne Et Al US007.404987B2 (12) United States Patent (10) Patent No.: US 7.404,987 B2 Karunaratne et al. (45) Date of Patent: *Jul. 29, 2008 (54) WHITE PEARLESCENT PAINT 5,626,661 A 5/1997 Schmid et al. COMPOSITIONS AND COATINGS 5,688,314 A 1 1/1997 Nishimagi et al. 5,702,519 A 12/1997 Nitta et al. 5,718,950 A 2, 1998 Komatsu et al. (75) Inventors: Nirupama Karunaratne, Ontario (CA); 5,733,364 A 3, 1998 Schmid et al. Ken Johnson, Ontario (CA); Hiroki 5,871,827 A 2f1999 Jaffe et al. Kanaya, Saitama (JP) 5,958,125 A 9, 1999 Schmid et al. 5,964,936 A 10, 1999 Reisser (73) Assignee: Honda Motor Co., Ltd., Tokyo (JP) 6,139,614 A 10/2000 Schmid et al. 6,176,918 B1 1/2001 Glausch et al. (*) Notice: Subject to any disclaimer, the term of this 6,238,472 B1 5, 2001 Andes et al. patent is extended or adjusted under 35 6,280,520 B1 8/2001 Andes et al. U.S.C. 154(b) by 484 days. 6,291,065 B1 9, 2001 Poetsch et al. 6,294,010 B1 9, 2001 Pfaffetal. This patent is Subject to a terminal dis 6,350,509 B1 2/2002 Sada et al. claimer. 6,398,862 B1 6/2002 Hechler et al. 2001/0033892 A1 10/2001 Iizuka ........................ 427,140 2002.0043464 A1 4/2002 Miyatake (21) Appl. No.: 10/665,365 2002/0076546 A1 6/2002 Johnson (22) Filed: Sep. 22, 2003 2004/0116554 A1 6/2004 Karunaratne et al. ........ 523,171 FOREIGN PATENT DOCUMENTS (65) Prior Publication Data DE 4432225 A1 3, 1996 US 2004/O116554 A1 Jun. 17, 2004 EP 116O295 A1 6, 2001 GB 1032057 6, 1966 (51) Int. Cl. GB 236O783. A 2, 2001 B05D 700 (2006.01) GB 2397O66 T 2004 B05D 7/16 (2006.01) JP O3076764 4f1991 B05D L/36 (2006.01) JP 11-10081 1, 1999 (52) U.S. Cl. .............. 427/407.1; 427/419.1; 427/419.2: WO WO97,29059 2, 1997 427/419.5 WO WOO224777 A2 9, 2002 (58) Field of Classification Search .............. 427/376.2, ZA 94505 8, 1994 427/376.6, 385.5, 418, 419.2, 407.1 See application file for complete search history. * cited by examiner Primary Examiner William P Fletcher, III (56) References Cited (74) Attorney, Agent, or Firm Morgan, Lewis & Bockius U.S. PATENT DOCUMENTS LLP 2,662,027 A 12, 1953 Pike (57) ABSTRACT 3,627,553 A 12/1971 Clarket al. 3,709,709 A 1/1973 Torok et al. 3,718,494 A 2f1973 Jacobson A pearlescent paint composition comprising a film-former 3,861,946 A 1/1975 Waitkins et al. and a solids material comprising a pearlizing effective 3,953,643 A 4, 1976 Cheung et al. amount of a pearlizing compound, a hiding material and a 4,359,504 A 1 1/1982 Troy pigment, the improvement wherein the pigment is white and 4,373.963 A 2f1983 Uenishi et al. the hiding material is selected from the groups consisting of 4.416,940 A 1 1/1983 Loye et al. metals selected from particulate aluminum, zinc, copper, 4,499,143 A 2f1985 Panush nickel, stainless steel and alloys thereof, and compounds 4,546,007 A 10, 1985 Abe et al. selected from aluminum oxide, aluminum silicate, hydrated 4,551.491 A 11, 1985 Panush 4,615,940 A 10, 1986 Panush et al. magnesium aluminum silicate, silica, mica aluminum sili 4,780,140 A 10, 1988 Franz et al. cate, magnesium oxide, calcium carbonate, calcium Sulphate, 4,814,208 A 3/1989 Miyazaki et al. calcium metasilicate, anhydrous sodium potassium alumi 4,952,245 A 8, 1990 Iwano et al. num silicate, sodium aluminum silicate, alumina trihydrate 4,978,394 A 12/1990 Ostertaget al. and barium Sulphate in, respective, effective whitening and 4,978,708 A * 12/1990 Fowler et al. ............... 524,507 hiding amounts. Preferably, the pearlizing compound is a 5,009,711 A 4, 1991 Emmert et al. mica, the hiding material is particulate aluminum and the 5,025,041 A 6/1991 Pfenninger et al. white pigment is titanium. The combination of the three types 5,234,496 A 8, 1993 Keiser of compounds in the desired pearlescent finishes, particularly 5,266,107 A 11/1993 Hoffman on vehicle bodies, provides the most advantageous option of 5,556,527 A 9/1996 Igarashi et al. 5,607,504 A 3, 1997 Schmid et al. requiring only a two-coat System. 5,624.486 A 4/1997 Schnid et al. 5,624,731 A 4/1997 Desjardins 11 Claims, 12 Drawing Sheets U.S. Patent Jul. 29, 2008 GILIHAA--*-- (ITIOO–o– (uu007-00€)VLVCIGIONVILLIINSNVRILAn i -08 d d C We w ea HONW.L.LASNWRL /6 U.S. Patent Jul. 29, 2008 Sheet 2 of 12 US 7.404,987 B2 s Z en O d o o S O d 5 s U.S. Patent Jul. 29, 2008 Sheet 3 of 12 US 7.404,987 B2 ÅTNOVOIWN (8IOZ10?)O) (umu00L-00†)GIONVALLIWSNVHLAQ% 00ub???uusubuL94, -----------------¬-------------------------------------------—––––––––1-07I upuaa AeA U.S. Patent US 7.404,987 B2 U.S. Patent Jul. 29, 2008 Sheet 5 of 12 US 7.404,987 B2 U.S. Patent Jul. 29, 2008 Sheet 7 of 12 US 7.404,987 B2 09€.099 |-001 -06 abue usue. A U.S. Patent Jul. 29, 2008 Sheet 8 of 12 US 7.404,987 B2 -07I a3L buSub.L. 9/ U.S. Patent Jul. 29, 2008 Sheet 9 of 12 US 7.404,987 B2 U.S. Patent Jul. 29, 2008 Sheet 10 of 12 US 7.404,987 B2 ...*.***** U.S. Patent Jul. 29, 2008 Sheet 11 of 12 US 7.404,987 B2 applying at least one base layer to a surface to provide the vehicle body surface with a surface Colour; identifying defect regions on the base layer in need of remedial repair, applying a remedial base layer patch in the defect region; Sanding the base layer patch to a roughness not exceeding 500 grit, thereby forming an intermediate base layer but without finishing the base layer applying a remedial pearlescent layer on the intermediate base layer. F.G. O. U.S. Patent Jul. 29, 2008 Sheet 12 of 12 US 7.404,987 B2 30 35 40 45 PANTFLM THCKNESS FIG. 11 US 7,404,987 B2 1. 2 WHITE PEARLESCENT PANT longer, a larger physical plant space is needed through which COMPOSITIONS AND COATINGS to run the assembly line. In manufacturing plants where physical space is at a premium, it may not be possible to set RELATED APPLICATIONS aside additional assembly line length to facilitate multiple 5 times between the application of multiple paint coats. The entire subject matter of U.S. Provisional application Accordingly, it may not be feasible to offer certain paint Ser. No. 60/334,422 filed Nov. 29, 2001 and entitled WHITE finishes on vehicles manufactured at Some Smaller manufac PIGMENT FOR USE INFORMULATIONS INCLUDING turing plants. WHITE PEARLESCENT PAINT is incorporated by refer U.S. Pat. No. 5,871,827 to Jaffe et al. of which the entire ence. The applicant claims priority benefit under Title 35, 10 Subject matter is incorporated herein by reference, discloses United States Code, Section 119(e) of U.S. Provisional appli two-coat and three-coat automotive finishes and a process for cation Ser. No. 60/334,422 filed Nov. 29, 2001 and entitled their preparation, wherein polychromism is achieved by WHITE PIGMENT FOR USE IN FORMULATIONS incorporating an opaque light interference pigment into the INCLUDING WHITE PEARLESCENT PAINT. top coat or mid coat. The processes taught by Jaffe involve the The entire subject matter of PCT application serial number 15 use of two coating layers, in which the first contains an PCT/CAO2/O1810, filed Nov. 29, 2002 and entitled WHITE opaque white, black or coloured pigment to achieve total PIGMENT FOR USE INFORMULATIONS INCLUDING hiding, while the second layer, being an interference pigment WHITE PEARLESCENT PAINT and designating the United does not hide the first coating. A clear topcoat is still applied States, is incorporated by reference. The applicant claims over the pigmented coats in order to complete the finish. The priority benefit under Title 35, United States Code, Section particles of opaque interference pigment taught are multi 120 of PCT application serial No. PCT/CAO2/01810, filed layered particles having an opaque layer coated with a trans Nov. 29, 2002 and entitled WHITE PIGMENT FOR USE IN parent dielectric layer, which in turn are coated with a semi FORMULATIONS INCLUDING WHITE PEARLESCENT transparent layer. This would be a relatively complex and PAINT and designating the United States. expensive coating process to apply, while the result of the 25 process gives polychromatic paint effects. FIELD OF THE INVENTION U.S. Pat. No. 5,350,509 to Sada et al., of which the entire Subject matter is incorporated in by reference, discloses a This invention relates to white pearlescent paints, lacquers coating structure that includes a colour base, a first coating and primers; their use in an improved process for creating a layer placed on the colour base, having transparent brilliant white “pearl’ finish on a painted or lacquered surface; and 30 members contained in the first coating layer, each brilliant substrates, particularly vehicle bodies, obtained by said pro member including an alternate lamination of at least two cess with said paint. polymers having different refractive indexes and controlling interference light resulting from reflection interference pro BACKGROUND OF THE INVENTION duced by alternate lamination and transmitted light other than 35 interference light.
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