Patent ID: 7935291
Filing Date: 2011-05-03
Classification: B29C,B29L,B32B

Abstract:
1. A process for producing polymer moldings (M/T/B) with functional surfaces (O) for which (I) a coating (B) is produced on a thermoplastic support sheet (T) by a process comprising (II) inserting the resulting coated thermoplastic support sheet (T/B) into an open mold, wherein the coated thermoplastic support sheet (T/B) or the cut-to-size pieces thereof are preformed prior to step (II), (III) closing the mold and contacting the uncoated side (T.2) of the coated thermoplastic support sheet (T/B) with a liquid polymeric material (M) to shape the coated thermoplastic support sheet (T/B) and join it firmly to the polymeric material (M), and causing the polymeric material (M) to solidify, and (IV) removing from the mold, the resulting coated polymer molding (M/T/B), whose coating (B) is uncured, part-cured or full-cured; the coating (B) being covered at least temporarily with a protective sheet (S), wherein the protective sheet (S) is applied to the coating (B) after step (I) and before the coated thermoplastic support sheet (T/B) is preformed and wherein the protective sheet (S) comprises a layer selected from the group consisting of films made of polyethylene, polypropylene, ethylene copolymers, propylene copolymers, and ethylene-propylene copolymers, and wherein the protective sheet has (s.1) a storage modulus E′ of from 10 (s.2) an elongation at break of from 400 to 900% at 23° C. longitudinally and transversely to the preferential direction produced by means of directed production processes in the production of (S), (s.3) a transmittance >70% for UV radiation and visible light with a wavelength of from 230 to 600 nm for a film thickness of 50 μm; wherein the coating (B)-facing side (S.1) of the protective sheet (S) has (s.1.1) a hardness <0.06 GPa at 23° C., and (s.1.2) a roughness corresponding to an R wherein the film (B.2) is fully or partly cured with UV radiation after step (I), but before step (II), following deformation to adapt the coated thermoplastic support sheet (T/B) to the contour of the mold, wherein the resulting full-cured coating (B.2) is optionally after-cured after step (IV) or the resulting part-cured coating (B.2) is fully cured after step (IV), and the resulting polymer molding (M/T/B) is optionally thermally after-treated to raise the crosslink density of (B.2), wherein the functionality of the surface (O) of the polymer moldings (M/T/B) is one which imparts at least one of color, effect, electroconductivity, magnetic shielding, inhibition of corrosion, fluorescence, or phosphorescence, and wherein the polymer moldings are designed for use in a means of transport selected from the group consisting of watercraft, rail vehicles, aircraft, cycles, motorcycles, automobiles, trucks, and buses.