Coating film for coating on a three-dimensionally curved substrate

Abstract

The invention relates to a process for applying coating films to three-dimensionally curved substrates, and to a process for producing coating films. In order to apply the coating film, which has at least a coating layer and an adhesive layer, the radiation-curable coating layer of the coating film is partially cured so as to be free from tack before being applied to the substrate. Following application, the coating film is subjected to electromagnetic radiation at below the wavelength of the visible spectrum and is fully cured. To produce a coating film, the coating layer is partially cured so as to be free from tack and in this state is stored until it is applied to a substrate. The coating layer can be attached at least indirectly to a smooth support base in conjunction with an adhesive layer. The coating layer and/or the coating film can be detached from a roller in applying the coating film to a substrate.

We claim:  
     
         1 . A method for coating a three-dimensionally curved surface of a dimensionally stable substrate comprising applying a coating film to the substrate and subjecting the coating film to electromagnetic radiation outside the visible spectrum, wherein the coating film comprises (a) a coating layer that comprises a partially cured, radiation-curable polymer and (b) an adhesive layer.  
     
     
         2 . A method as claimed in  claim 1 , wherein the coating layer of the coating film is heated to the glass transition temperature or slightly above the glass transition temperature of the polymer.  
     
     
         3 . A method as claimed in  claim 1 , wherein the polymer of the coating layer has a glass transition temperature of below 40° C.  
     
     
         4 . A method as claimed in  claim 1 , wherein the coating layer comprises a multi-layer structure having an outside layer comprising a fully cured clearcoat.  
     
     
         5 . A method as claimed in  claim 4 , wherein at least one layer of the multi-layer structure comprises a colored thermoplastic polymer material in the thermoplastic state.  
     
     
         6 . A method as claimed in  claim 4 , wherein the outside layer comprises a fully cured thermosetting polymer.  
     
     
         7 . A method as claimed in  claim 6 , wherein the outside layer further comprises a binder material.  
     
     
         8 . A method as claimed in  claim 7 , wherein the binder material comprises one or more of the group consisting essentially of phosphazene, a phosphazene resin, a phosphazene derivative, a phosphazene intermediate, a urethane, a urethane derivative, a urethane intermediate, an acrylate, an acrylate derivative, and an acrylate intermediate.  
     
     
         11 . A method as claimed in  claim 1 , wherein the coating film further comprises a supporting film, and wherein the support base is detached from the coating film prior to applying the coating film to the substrate.  
     
     
         12 . A method as claimed in  claim 11 , wherein the adhesive layer is added to the coating film before the support base detaches from the coating film.  
     
     
         13 . A method as claimed in  claim 11 , wherein the adhesive layer is first attached to the support base and thereafter the coating layer is attached to the adhesive layer.  
     
     
         14 . A method as claimed in  claim 1 , wherein the adhesive layer and a pre-cured coating layer are attached to a support base, and wherein the coating layer is partially cured after the being detached from the support base.  
     
     
         15 . A method as claimed in  claim 1 , wherein the coating layer is partially cured while attached to a support base.  
     
     
         16 . A method as claimed in  15 , wherein the adhesive layer is attached to the coating layer after the coating layer is detached from the support base.  
     
     
         17 . A method as claimed in  claim 8 , wherein the coating film further comprises a support base, and wherein the support base is detached from the coating film prior to applying the coating film to the substrate.  
     
     
         18 . A method as claimed in  claim 8 , wherein the adhesive layer is added to the coating film before the support base detaches from the coating film.  
     
     
         19 . A method as claimed in  claim 8 , wherein the adhesive layer is first attached to the support base and thereafter the coating layer is attached to the adhesive layer.  
     
     
         20 . A method as claimed in  claim 8 , wherein the adhesive layer and a pre-cured coating layer are attached to a support base, and wherein the coating layer is partially cured after the being detached from the support base.  
     
     
         21 . A method as claimed in  claim 8 , wherein the coating layer is partially cured while attached to a support base.  
     
     
         22 . A method as claimed in  21 , wherein the adhesive layer is attached to the coating layer after the coating layer is detached from the support base.  
     
     
         23 . A coating film comprising a coating layer having a partially-cured polymer material and an adhesive layer, where the coating film is capable of being applied to a substrate without a support base.  
     
     
         24 . A coating film as claimed in  claim 23 , wherein the coating layer comprises a multi-layer structure.  
     
     
         25 . A coating film as claimed in  claim 23 , wherein the coating layer comprises a binder material.  
     
     
         26 . A coating film as claimed in  claim 23 , wherein the coating layer comprises a thermosetting polymer or a thermoplastic polymer.