POLYMER-BASED SUBSTRATE AND METHOD FOR PRODUCING THE SAME

Abstract

A polymer-based substrate is proposed, which in particular is electrostatically coatable, wherein the substrate has a substrate base body made using a polymeric material and a two- or multi-layer coating applied to a surface region of the substrate base body, wherein a first layer of the coating is configured as a bonding layer and is arranged in contact with the surface region of the substrate base body, wherein a second layer of the coating is configured as a lacquerable cover layer, wherein at least one layer of the coating is produced as a layer with reduced surface resistance using a proportion of an electrically non-insulating material, such that it results in a specific surface resistance of this layer of about 10.sup.10 Ohm or less, and wherein at least one layer of the coating is configured as a film.

Claims

1. A polymer-based substrate, comprising a substrate base body made using a polymeric material and a two- or multi-layer coating applied to a surface region of the substrate base body, wherein a first layer of the coating is configured as a bonding layer and is arranged in contact with the surface region of the substrate base body, wherein a second layer of the coating is configured as a lacquerable cover layer, wherein at least one layer of the coating is produced as a layer with reduced surface resistance using a proportion of an electrically non-insulating material, such that it results in a specific surface resistance of this layer of about 1010 Ohm or less, and wherein at least one layer of the coating is configured as a film.

2. The substrate in accordance with claim 1, wherein the bonding layer is configured as an adhesive layer, a primer layer with an adhesive layer, or as a layer that is weldable to the substrate base body.

3. The substrate in accordance with claim 1, wherein the specific surface resistance of the layer with reduced surface resistance is about 109 Ohm or less.

4. The substrate in accordance with claim 1, wherein the electrically non-insulating material that is used for producing the layer with reduced surface resistance is a metallic material and wherein the layer with reduced surface resistance has a thickness of about 500 nm or less.

5. The substrate in accordance with claim 1, wherein the layer with reduced specific surface resistance comprises a non-metallic electrically conductive or semi-conductive material, which is selected from a) conductive carbon materials, selected from conductive soot, graphite, graphene, carbon nanotubes (CNT), or a carbon nanotubes (CNT) or a carbon layer; b) conductive inorganic materials, selected from conductive tin oxides; c) intrinsically conductive polymers; and/or d) conductively equipped polymeric materials, comprising a non-conductive polymer and an additive reducing the electrical resistance of the non-conductive polymer, which additive is selected from conductive soot, graphite, graphene, CNT, and conductive inorganic materials and intrinsically conductive polymers.

6. The substrate in accordance with claim 1, wherein the layer with electrically conductive material comprises a fiber material with electrically conductive or semi-conductive fibers wherein the fiber material comprises metal fibers, fibers of conductive polymer, conductively equipped polymer fibers, CNT, and/or carbon fibers.

7. The substrate in accordance with claim 1, wherein the first layer of the two- or multi-layer coating is produced as a bonding layer using an electrically conductive or semi-conductive material.

8. The substrate in accordance with claim 1, wherein the second layer is produced with a cover layer using an electrically conductive or semi-conductive material.

9. The substrate in accordance with claim 1, wherein the two- or multi-layer coating has a layer which comprises a plastic material based on a polyolefin on EVA, on a polyester on a polyamide on a vinyl polymer and/or on a copolymer of the aforementioned polymers.

10. The substrate in accordance with claim 1, wherein the two- or multi-layer coating comprises a layer with a reinforcing material, wherein the reinforcing material is from reinforcing fibers.

11. The substrate in accordance with claim 1, wherein one of the layers of the two- or multi-layer coating is a monoaxially or biaxially stretched film.

12. The substrate in accordance with claim 1, wherein the surface of the cover layer of the second layer of the two- or multi-layer coating is pretreated to improve the bonding of a lacquer layer.

13. The substrate in accordance with claim 1, wherein the two- or multi-layer coating on the surface region of the substrate base body has a thickness of about 200 m or less.

14. The substrate in accordance with claim 1, wherein the sum of the products of the respective thickness of a layer and the value of the thermal conductivity of the respective layer for all layers of the coating results in a total value of about 110-4 W/K or less.

15. The substrate in accordance with claim 1, wherein the two- or multi-layer coating is detachably connected to the substrate base body.

16. The substrate in accordance with claim 1, wherein the two- or multi-layer coating is non-detachably connected to the substrate base body.

17. The substrate in accordance with claim 1, wherein the two- or multi-layer coating is configured as a diffusion barrier against outgassing from the substrate base body.

18. The substrate in accordance with claim 1, wherein the substrate is configured as a heat-insulating profile.

19. The substrate in accordance with claim 1, wherein the substrate has a powder lacquer layer which has a layer thickness in the range of about 10 m to about 300 m.

20. The substrate in accordance with claim 19, wherein the powder lacquer layer is applied to the cover layer of the two- or multi-layer coating with a lacquer coverage of about 90% or more.

21. A method for producing an electrostatically powder lacquerable polymer-based substrate, wherein the method comprises: providing a polymer-based substrate base body which comprises a polymeric material with a first polymer, applying a two- or multi-layer coating, comprising a first layer as a bonding layer and a second layer as a lacquerable cover layer on a surface region of the substrate base body of the substrate to be coated, wherein the bonding layer of the first layer is brought into contact with the surface region of the substrate base body, wherein at least one layer of the coating is produced as a layer with reduced surface resistance using a proportion of an electrically non-insulating material, such that it results in a specific surface resistance of this layer of about 1010 Ohm or less, and wherein at least one layer of the coating is configured as a film.

22. The method in accordance with claim 21, wherein the two- or multi-layer coating is applied to a surface region of the substrate base body, which is provided for a subsequent powder lacquering.

23. The method in accordance with claim 21, wherein the two- or multi-layer coating is applied to a surface region of the substrate base body, which is arranged substantially in parallel to a surface region that is provided for a subsequent powder lacquering.

24. (canceled)

25. The method in accordance with claim 21, wherein first the first layer is applied with the bonding layer to the substrate base body and wherein subsequently the second layer of the coating is applied to the first layer.

26. The method in accordance with claim 21, wherein the substrate is connected to at least one metal profile and wherein the two- or multi-layer coating is applied to the substrate base body in such a way that, after connecting the substrate to the metal profile, the layer of the coating with a reduced specific surface resistance has a physical contact with the metal profile.

27. The method in accordance with claim 21, wherein the substrate base body is connected to at least one metal profile and wherein the layer of the two- or multi-layer coating with reduced surface resistance after connecting the substrate base body to the metal profile, is applied to the substrate base body in such a way that the two- or multi-layer coating in particular has a physical contact with the metal profile.

28. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0130] In the drawings:

[0131] FIGS. 1A to 1E show a schematic depiction of the production of a substrate in accordance with the invention in multiple variations;

[0132] FIGS. 2A to 2F show further embodiments of a substrate in accordance with the invention as part of metal-plastic composite profiles;

[0133] FIGS. 3A and 3B show schematic representations of embodiments of two-layer coatings for producing substrates in accordance with the invention;

[0134] FIGS. 4A to 4G show a plurality of embodiments of multi-layer coatings for producing substrates in accordance with the invention;

[0135] FIGS. 5A to 5D show detailed representations of a section of FIG. 2A in multiple variants;

[0136] FIGS. 6A to 6D show powder lacquered substrates in accordance with the invention with different lacquer coverages; and

[0137] FIG. 7 shows a schematic depiction of a measurement setup for determining the surface resistance in an accelerated method.

DETAILED DESCRIPTION OF THE DRAWINGS

[0138] The figures described in detail in the following are schematic representations that are not true to scale and in particular do not depict the real relationships of the layer thicknesses of the layers among each other. The layer sequences shown are examples and can be widely varied in accordance with the invention. With regard to the nomenclature, within the meaning of the invention, a first and a second layer are discussed here, referring to the definitions made in claim 1. There may be further layers between the first layer in accordance with the invention and the second layer in accordance with the invention, thus a second layer of the coating from the geometric sequence does not necessarily have to represent the second layer of the coating within the meaning of the invention.

[0139] FIGS. 1A to 1E shows with the example of a so-called insulating profile in different variations a substrate 10, 30, 50, 70, 90 in accordance with the invention in the different sub-FIGS. 1A, 1B, 1C, 1D and 1E, which all have a substrate base body 12 that in cross section perpendicular to its longitudinal direction has an offset configuration on both sides, wherein so-called roll-in projections 14 and 16 are moulded onto both rim regions of the offset part.

[0140] The substrate base body 12 is typically extruded, optionally also pultruded, and then already has the shape shown in FIGS. 1A to 1E with the offset cross section and the moulded-on roll-in projections 14 and 16.

[0141] In accordance with the invention, a two- or multi-layer coating 18, 38, 58, 78, and 98, respectively, which is configured differently in FIGS. 1A, 1B, 1C, 1D, and 1E, is applied to this substrate base body 12.

[0142] In FIG. 1A, the two- or multi-layer coating 18 extends with its rim regions 20 and 22 up to the one roll-in projection 14 and the other roll-in projection 16, respectively. As a result, upon connecting the substrate 10 to metal profiles by rolling in, a physical contact of the metal profiles with the two- or multi-layer coating 18 can be produced, as is described in detail in connection with FIG. 2A.

[0143] In FIG. 1B, a two- or multi-layer coating 38 extends with its rim regions 40, 42 up to and around the roll-in projections 14 and 16.

[0144] In FIG. 1C, a variant of the substrate 50 in accordance with the invention is shown, in which the insulating profile (substrate) 50 is provided with a coating 58, which still covers a part of the offset region of the insulating profile 50 with its rim regions 60, 62, though is not tangential to the regions of the roll-in projections 14 and 16, but on the contrary maintains a distance from said roll-in projections 14 and 16, said distance being sufficient in the rolled-in state so as to avoid a physical contact with the metal profiles (see FIG. 2C).

[0145] In FIG. 1D, an example of a substrate 70 in accordance with the invention is shown, in which the insulating profile (substrate 70) in cross section is covered by a coating 78 only halfway, said coating 78 in turn extending to one of the roll-in projections, the roll-in projection 16, from the rim region 82 of the coating 78. Again as in the embodiment in FIG. 1A, after rolling-in, it is achieved that a physical contact between the coating 78 or the rim region 82 thereof and the metal profile is produced.

[0146] A further embodiment of the substrate 90 in accordance with the invention is shown in FIG. 1E, in which the coating covers only selected regions of the surface of the substrate base body 12, wherein the coating 98 is divided here into four strip shaped coating elements 100, 101, 102, 103, which are arranged in parallel to each other and extend in the longitudinal direction of the substrate.

[0147] In this embodiment of FIG. 1E too, a physical contact of the coating 98 with the metal profiles in the rolled-in state is avoided, as can be seen analogously in the illustration 2D.

[0148] In FIGS. 2A to 2F, in the sub-FIGS. 2A, 2B, 2C, 2D, 2E, and 2F different embodiments of substrates in accordance with the invention are shown, which are connected to metal profiles to form a plastic-metal composite profile. These composite profiles are designed to, after the assembly shown in FIGS. 2A to 2F, be coated together both in the region of the substrate in accordance with the invention and in the region of the corresponding metal profiles with a lacquer layer, in particular a powder lacquer layer.

[0149] The details of the different embodiments of FIGS. 2A to 2F are as follows:

[0150] FIG. 2A shows a metal-plastic composite profile 110 with a substrate 10 in accordance with the invention and a first and a second metal profile 114, 116, which are connected to the roll-in projection 14 and the roll-in projection 16, respectively, of the substrate in accordance with the invention or insulating profile 10 by means of rolling-in.

[0151] The roll-in projections 14 and 16 are thereby inserted into grooves 118, 119 of the metal profiles 114 and 116, respectively, and then are fixed by means of a rolling-in process by means of positive- and/or force-locking due to a deformation of the profile parts 115 and 117 of the metal profiles 114 and 116 called a roll-in hammer.

[0152] A physical contact of the metal profiles 114 and 116 with the two- or multi-layer coating 18 of the insulating profile 10 is hereby achieved.

[0153] If the metal profile(s) is/are provided with a sharp-toothed knurling, with sufficient pressure when rolling in, an electrically conductive contact of the electrically conductive layer to the metal profile(s) can then be formed even if the coating has an electrically insulating cover layer, i.e., a layer with a specific surface resistance greater than 10.sup.10 Ohm.

[0154] In FIG. 2B, a metal-plastic profile 120 is shown, in which the substrate 30 in accordance with the invention in the form of an insulating profile is connected to a first metal profile 124 and a second metal profile 126.

[0155] The composite is hereby achieved by inserting the roll-in projections 14 and 16 of the insulating profile 30 into the grooves 128, 129 and then rolling in, wherein a physical contact of the metal profiles 124 and 126 with the two- or multi-layer coating 38 of the insulating profile 30 is produced. The physical contact between the metal profiles 124, 126 and the two- or multi-layer coating 38 of the insulating profile 30 is possible here over a larger area, because the rim regions 40, 42 of the two- or multi-layer coating 38 extend over a larger area of the roll-in projections 14, 16.

[0156] In contrast thereto, in the embodiment of FIG. 2C a metal-plastic composite profile 130 is provided in which a substrate in accordance with the invention in the form of an insulating profile 50 is connected by way of its roll-in projections 14 and 16 to a first metal profile 134 and a second metal profile 136, as was already described, by way of a roll-in connection.

[0157] The two- or multi-layer coating 58 of the insulating profile 50 has rim regions 60, 62 which maintain a distance from the metal profiles in the installed state of the metal-plastic composite profile 130.

[0158] While in the embodiments of FIGS. 2A and 2B a physical contact of the layer with reduced surface resistance of the two- or multi-layer coating 18 and 38, respectively, with the metal profile or metal profiles is produced, which contact may also be electrically conductive, in the embodiment of FIG. 2C the possibility of an electrically conductive connection between the metal profiles 134, 136 on the one hand and the layer with reduced surface resistance of the coating 58 on the other hand is deliberate foregone, such that a capacitive mechanism is used here in an electrostatic powder coating.

[0159] The same principle is used with a metal-plastic composite profile 140, as shown in FIG. 2D, in which an insulating profile 142 is used together with two metal profiles 144, 146 and the connection between the metal profiles on the one hand and the insulating profile 142 on the other hand is again achieved by rolling in the roll-in projections 14 and 16 of the substrate base body 12.

[0160] In this embodiment of the substrate/insulating profile 142 in accordance with the invention, provision is made for a two- or multi-layer coating 148 to be applied only to the region of the insulating profile 142 that is not offset, such that the spatial distance of the rim regions of the coating 148 from the metal profiles 144 and 146 is even more significant than in the embodiment of FIG. 2C. In this embodiment of FIG. 2D, again the capacitive mechanism is used in an electrostatic powder coating.

[0161] In a further embodiment, a metal-plastic composite profile 160 is used in FIG. 2E, in which the substrate base body 12 is first connected with the roll-in projections 14 and 16 to a metal profile 164 and a further metal profile 166 by means of rolling-in. Only after that is a two- or multi-layer coating 168 performed both on a surface region of the substrate base body 12 and reaching beyond that with rim regions 170, 172 on surface regions of the metal profiles 164 and 166, respectively. In this embodiment too, again a physical and optionally electrically conductive contact is produced between the coating 168 on the one hand and the metal profiles 164 and 166 on the other hand.

[0162] In this example, the metal profile 166 is provided with an adapted shape in order to create a particularly homogeneous, appealing appearance of the metal-plastic composite profile 160, in which the two- or multi-layer coating 168 flushly adjoins a projection 167 of the metal profile 166.

[0163] Furthermore, this embodiment shows that the coating 168, according to the invention, does not necessarily have to abut the surface of the substrate base body 12 over the entire area, but may also maintain a distance therefrom, e.g., in the region of continuous grooves, undercuts, channels, recesses, through-openings, or sharp bends and radii at projections or protrusions, as is shown in FIG. 2E, in which the coating does not abut the substrate base body over the entire area.

[0164] Finally, FIG. 2F shows a metal-plastic composite profile 180 in which a substrate in accordance with the invention in the form of an insulating web 182 is used, which on the one hand comprises a substrate base body 12 with roll-in projections 14 and 16 moulded thereon, which each are again connected to the metal profiles 184, 186 by way of a roll-in connection.

[0165] On the other hand, however, a two- or multi-layer coating 188 was applied to the substrate base body 12 of the insulating profile 182 before the assembly (rolling-in) thereof, but on a surface of the substrate base body 12 which extends in parallel to the surface 189 of the substrate base body that is to be provided later with a lacquer layer. Here too, provision is made for the two- or multi-layer coating 188 to be in physical contact with the metal profiles 184 and 186, such that an electrically grounded mechanism can optionally be used here in the electrostatic coating.

[0166] For the sake of simplicity, electrostatically applied lacquer layers are not shown in the depictions of FIG. 2. In these examples shown, said lacquer layers are applied to the surfaces of the metal-plastic composite profiles equipped with the two or multi-layer coating, which surfaces are arranged on top in the draw direction.

[0167] FIGS. 3A to 3B shows two alternatives for a two-layer coating, which can be used in the substrates in accordance with the invention, in particular those shown in FIGS. 1 and 2, wherein in FIG. 3A a coating 190 with a first layer 192 is shown, which is configured as a layer that imparts a bond (bonding layer), and a second layer 194, which is produced using a material that reduces the specific surface resistance of said layer 194 to a value of about 10.sup.10 Ohm or less.

[0168] For this type of coating, in particular a polymeric material, for example PET, in particular in the form of a film, filled with conductive soot is suitable for the layer 194.

[0169] In an alternative arrangement of the layers as is shown in the two-layer coating 195, in accordance with FIG. 3B a first layer 196 is provided in the form of a bonding layer, which simultaneously performs the function of a layer with reduced surface resistance. As a second layer 198, a cover layer, e.g., in the form of a polymer film, is used here which functions as a protective layer for the first layer (bonding layer) 196 with reduced surface resistance.

[0170] If the layer with reduced surface resistance is not simultaneously the layer forming the cover layer in a two- or multi-layer coating in accordance with the invention, the specific surface resistance can thus not be measured directly on the surface of the coating. In this case, it is recommended to, e.g., mechanically separate the layer structure of the coating (delaminate) in order to be able to measure the specific surface resistance directly on the then exposed dissipative layer or the layer with reduced surface resistance.

[0171] A plurality of variants of multi-layer coatings are shown in FIGS. 4A to 4G, which also may be used in substrates in accordance with the invention, in particular those shown in FIGS. 1 and 2.

[0172] According to the depiction of FIG. 4A, a multi-layer coating 200 is provided, which is of a three-layer construction and comprises, in addition to a first layer 202 that is configured as a bonding layer, a further layer 204 with reduced surface resistance placed thereon, which is finally overlaid with a second layer that is configured as a cover layer 206. In this embodiment of the multi-layer coating, the selection of materials for reducing the surface resistance in the further layer 204 may be made from a wide range of materials, in particular from metallic materials which, as the case may be, would be subject to corrosion upon further processing, because they are completely covered and protected by the cover layer 206. This layer structure can be easily represented, for example, from a thin metallized polymer film, which on the side of the metallization 204 is provided with an adhesive system 202 as a bonding layer (first layer), wherein the polymer film 206 then functions as the second layer or cover layer.

[0173] In FIG. 4B a four-layer embodiment is shown as a multi-layer coating 210 in which a layer 214 is applied as a support layer, made, e.g., of a polymer film, to a first layer 212 (bonding layer). A further layer 216 with reduced surface resistance is then arranged on said layer 214. The surface of the coating 210 then forms a cover layer 218 (second layer within the meaning of the invention), and this makes it possible to use materials that are sensitive to corrosion for reducing the surface resistance of the layer 216.

[0174] In FIG. 4C, essentially the layer structure of FIG. 4B is shown, though in the multi-layer coating 230, in addition to the first layer 232 (bonding layer), a layer 234 that is configured as a support layer, a further layer 236 with reduced surface resistance, and a layer as a connecting layer 238 are present, the latter made, e.g., of a laminating adhesive for better layer cohesion. This structure is again overlaid with a further layer 240, which has specific bonding properties for bonding a lacquer system to be applied. The layer structure of the embodiment of FIG. 4C can thereby be configured, e.g., as a self-adhesive film material, which can be applied to the substrate base body in a simple manner.

[0175] In the case of a multi-layer coating 250 of FIG. 4D, in the structure of the coating 250 first a first layer 252 is provided as a bonding layer, by way of which a further layer is arranged in the form of a support layer 254. A layer with reduced surface resistance is then arranged on the support layer 254, which layer with reduced surface resistance is then in turn covered by a protective or support layer 258. The surface of the coating 250 is then formed by a layer 260 that is also configured having a reduced surface resistance.

[0176] The two layers 250, 260 with reduced surface resistance may then each contain different materials in different proportions, wherein in each case the specific surface resistance of a layer is set to the value of 10.sup.10 Ohm or less.

[0177] If the layer 260 is deliberately made of a non-inert metal such as, e.g., aluminum, an oxidation of this layer may be performed, among other things in an anodizing process. The resulting layer of an aluminum oxide in position 260 then forms a lacquerable cover layer, which due to the chemical structure of the aluminum oxide has good bonding properties for a lacquering. Because the internal layer 256 with reduced surface resistance remains intact due to the protective layer 258, the prerequisite for a good lacquer coverage remains fulfilled and a structure that then corresponds approximately to the one shown in FIG. 4C is obtained.

[0178] Finally, a multi-layer coating 270 is shown in FIG. 4E, which, building on a first layer 272 as a bonding layer, has a further layer 274 in the form of a support layer as well as a further layer 276 with reduced surface resistance placed thereon. A further layer 278 with the function of a layer holding the layer structure together is placed on this structure, said layer 278 being made, e.g., of a laminating adhesive, followed by a further layer 280 which has a reduced specific surface resistance.

[0179] The layer 280 with reduced surface resistance is overlaid with a further layer 282 that takes on the function of a further support layer, which is finally covered by a further layer 284 (the second layer within the meaning of the invention) that has the function of a cover layer and a layer that creates or ensures a bonding connection to a lacquer system that is later to be applied to the coating.

[0180] This structure can be designed so that the layers 274 and 282 are identical and optionally the layers 276 and 280 are also identical. This can be achieved in a simple manner such that, for example, two tracks of a plastic film that has been metallized on one side (metallization 276, 280 and plastic film 274, 282) are adhesively bonded against each other by means of a laminating adhesive 278. A first layer 272 and a further layer 284 can then be applied to this laminate.

[0181] FIG. 4F shows schematically the structure of a coating 300 to be used in accordance with the invention, with a first layer 302 as a bonding layer, a further layer 304 that is configured as a support layer, and a further layer 306 placed thereon, which has a reduced surface resistance.

[0182] Two further layers 308 and 310 are then applied on this layer 306, whichas was already described in FIG. 4Cfunction as a connecting layer and as a cover layer (or second layer within the meaning of the invention), wherein the latter has specific bonding properties for bonding a lacquer system to be applied.

[0183] In contrast to the coating structure of FIG. 4C, the two uppermost layers 308 and 310 are configured having a smaller width, so that there is an overhang 314, consisting of the layers 302, 304, and 306, on both sides of the coating 300, which overhang 314 makes it possible for the thus partially exposed layer 306 with reduced surface resistance to be able to be directly physically contacted by a metal profile and thus be electrically conductively brought into connection.

[0184] FIG. 4G shows a further exemplary structure of a coating 320 to be applied to the substrate base body in accordance with the invention, said coating 320 having a first layer 322 which is configured as a bonding layer. In this embodiment, as in all other embodiments of the invention, the first layer 322 may be applied to the substrate base body together with the further layers or separately, wherein the further layer(s) is/are then preferably placed together on the bonding layer 322.

[0185] In the structure of the coating 320, the first layer 322 is followed by a further layer 324 in the form of a PET film and a metallic layer 326 with reduced surface resistance made of aluminum. The following layer 328 is made of a laminating adhesive, which ensures a permanent bond of the layer 326 to the following layer 330. The layer 330 is a further layer with reduced surface resistance and is made of aluminum, the layer 332 again consisting of a PET film. A layer 336 with reduced surface resistance is connected to the already described layers by way of a layer 334 made of a laminating adhesive. Finally, a layer 338 made of a PET film forms as the first layer a lacquerable cover layer of the coating 320.

[0186] The use of more than one layer with reduced surface resistance has the advantage that the electrical capacity of the coating is increased, in a way that such coatings are recommended in particular when powder coating is to be applied according to a capacitive method. Likewise, the permeability, e.g., for water vapor can be reduced in a simple manner by means of such complex layer structures by there being a plurality of layers with a barrier effect, e.g., with an aluminum coating.

[0187] FIGS. 5A to 5D shows in detailed FIG. 5A a section of FIG. 2A, namely the part of the composite profile 110 in which the roll-in body 16 engages into the groove of the metal part 116, wherein a physical contact of the coating 18 with the so-called roll-in hammer 117 of the metal profile 116 is created there by rolling in.

[0188] This contact between the coating 18 and the roll-in hammer 117 or the metal profile 116 can be created in different ways, as is shown schematically in FIGS. 5B to 5D. A multi-layer coating is shown as the coating 18, which in the case of FIGS. 5B and 5C corresponds in layer structure to the structure that is schematically shown in FIG. 4C, while in the illustration 5D a coating 300 of FIG. 4F is used.

[0189] In FIG. 5B, a mechanical contact is produced between the roll-in hammer 117 of the metal profile 116 and the coating 18 and 230, respectively, wherein no electrically conductive connection between the metal profile 116 and the layer 236 with reduced surface resistance is produced here.

[0190] The situation is different in FIG. 5C, in which the surface of the roll-in hammer 117 of the metal profile 116 is knurled on the side contacting the coating and has a sort of tooth profile 320, which can penetrate through the two superficial layers 238, 240 and come into contact with the layer 236, such that an electrically conductive or dissipative contact between the metal profile 116 and the layer 236 with reduced surface resistance is also produced here.

[0191] In a further alternative that is shown in FIG. 5D, the coating 300, which is shown in FIG. 4F, is used as the coating 18, in which the overhang 314 at the rim of the coating 300 comes into physical contact with the roll-in hammer 117 during the roll-in operation, wherein, because the layer 306 with reduced surface resistance is exposed in the region 314, an electrically conductive contact between the metal profile 116 and the coating or the layer 306 is established.

[0192] FIGS. 6A to 6D shows for example the determination of the lacquer coverage of conventional substrates and substrates powder coated in accordance with the invention, wherein in FIG. 6A an optically microscopic image at 50 magnification can be seen, in which a white powder lacquer was applied to a conventional black substrate base body (without a coating in accordance with the invention). It is already apparent from the color structure or the pattern that the lacquer coverage is incomplete and the lacquer layer is divided into may individual or island-like regions.

[0193] As can be seen in FIG. 6B, this image of FIG. 6A is converted into a black and white image, and the same is then evaluated with respect to the white surface portions, which in this case results in a lacquer coverage of 47.2%.

[0194] FIG. 6C shows a substrate in accordance with the invention in the same resolution as in FIGS. 6A and 6B with a white lacquer coating applied on a coating in accordance with the invention, wherein in FIG. 6D the same surface is shown after a conversion into a black and white image. One can already clearly see here a homogeneous lacquer coverage. Here, a lacquer coverage of 100% was achieved under the same lacquering conditions as in the sample of FIG. 6A/B.

EXAMPLES

[0195] For producing coatings in accordance with the invention, the following materials were used:

[0196] Material A: Coating with a layer structure, as is shown in FIG. 4G. A film laminate is present, consisting of an about 40 m to 43 m thick stack of three plastic films (polyester films (PET), layers 324, 332, 338) each with a thickness of about 10 m to about 13 m), wherein each PET film is metallized with aluminum (thickness of the metallization per PET film in each case <80 nm, layers 326, 330, 336). The three metallized films are connected to each other by means of an acrylate adhesive (layers 328, 334) and then form the film laminate. The film laminate thus has three layers with reduced surface resistance. The second layer within the meaning of claim 1 is hereby an exposed PET layer (layer 338). Internal metallization layers are present due to the described laminate construction. A separate bonding layer of an acrylate-based bonding adhesive is selected as the first layer (layer 322), the layer thickness of which is about 20 m to about 30 m.

[0197] Material B: Coating with a layer structure as shown in FIG. 4A on the basis of a PET film with a thickness of about 10 m to about 15 m. The film (second layer 206) is metallized on one side with aluminum (layer 204), the thickness of the metallization is <40 nm. The metallized film (layers 204, 206) is adhered to a substrate base body by means of a separately applied cross-linking adhesive (bonding layer or first layer 202), such that the metallization directly adjoins the adhesive of the bonding layer. The metallization is thus an internal layer. The bonding layer is formed from the cross-linking adhesive (hybrid adhesive, consisting of a 1K moisture-cross-linking silane-terminated polymer) with an applied layer thickness of about 20 m to about 40 m.

[0198] Substrate base bodies: Commercially available insulating profiles (in the color black) of the type Insulbar REG and Insulbar LO18 of the company Ensinger GmbH were used as substrate base bodies. These insulating profiles consist of the materials TECATHERM 66GF (polyamide 66 with 25% glass fiber content) and TECATHERM LO (polyamide 66+polyphenylene ether blend with 20% glass fiber content (GF)). The moisture content of the plastic profiles and the substrate base bodies was quantified according to the Karl Fischer method (DIN EN ISO 15512).

[0199] In the following examples, the substrates and substrate base bodies are connected, as the case may be, to commercially available aluminum profiles by rolling in to form composite profiles.

[0200] The lacquering tests were performed with a white powder lacquer of the type SA816G Interpon D1036 (manufacturer: Akzo Nobel Powder Coatings GmbH). The powder lacquer was applied using a commercially available powder gun for electrostatic powder coating and was baked in an oven at 200 C. for 20 minutes.

[0201] For measurements by means of the accelerated method, a commercially available electrotechnical handheld measuring device, a so-called multimeter, here a multimeter of the type Fluke 177 (Fluke Deutschland GmbH), which then is operated in the mode resistance measurement. The experimental setup is shown schematically in FIG. 7 in connection with the measurement on a sample of a coating 230 of FIG. 4C, which is structured in accordance with the invention. The electrodes used typically have punctiform measuring tips.

[0202] Two electrodes 402, 404 with bare, punctiform measuring tips 406, 408 are connected to a measuring device 400 and are placed on the exposed surface 410 of the layer structure of the coating 230 that is to be tested at a distance X from each other, which is greater than the diameter of the measuring tips 406, 408 (X is 1 cm, for example). For this purpose, the layers 238 and 240 ware partially detached. The sample 230 must thereby lie on an electrically non-conductive base (e.g., a plate made of Plexiglas; not shown).

Example 1: Measurement of the Surface Resistances of Materials

[0203] Measurements of the respective surface resistance were performed on test samples in accordance with the invention and on test samples not in accordance with the invention. For this purpose, the measurement was performed using a measuring device according to DIN EN 61340-2-4 for determining the specific surface resistance, the measuring device having a lower measuring limit of about 110.sup.5 Ohm, as well as the accelerated method described above, with a measuring upper limit of about 510.sup.7 Ohm.

Example 1a (Reference): Measurement on a Commercial Insulating Profile Insulbar REG (without a Coating)

[0204] It is determined that no electrical conductivity or too high a surface resistance is present. The values are displayed in Table 1.

Examples 1b and 1c: Measurements on a Separate Multi-Layer Film Laminate (Material A) with an External PET Layer and Metallization Thereunder

[0205] This laminate may be used to produce a coating in accordance with the invention on a substrate base body. For an approximation calculation of the , thicknesses product, in sum a layer thickness of 42 m of polymer (PET film and acrylate laminating adhesive) with a value for the heat conductivity of 0.24 W/mK and three layers of aluminum, each 80 nm (i.e., a summed thickness of 240 nm of aluminum) with a value for the heat conductivity of 236 W/mK (pure aluminum) is assumed.

[0206] The result of 6.710.sup.5 W/K is below 110.sup.4 W/K and thus indicates minimal and therefore desired heat transfer. Even after including a bonding adhesive in order to adhesively bond the laminate to the surface of the base profile (assume: 30 m adhesive with 0.18 W/mK; yields an additional k-thickness product of 5.410.sup.6 W/K), with a total of 7.210.sup.5 W/K the limit value of 110.sup.4 W/K is not exceeded.

[0207] In Example 1b, the outer surface of the laminate, which constitutes a second layer in accordance with the invention, was tested for electrical conductivity. It is determined that no electrical conductivity or a too high (specific) surface resistance is present.

[0208] In Example 1c one of the internal metallized layers was preparatively exposed. For this purpose, the laminate was mechanically delaminated, so that the surface resistance of an internal metallized layer could be tested. This exposed aluminum-vapor deposited layer with reduced surface resistance then exhibited an electrical conductivity according to the two measuring methods.

Example 1d (Reference): Testing a Rolled Aluminum Film

[0209] This pure metal layer made of rolled aluminum then displayed an electrical conductivity according to both measuring methods. The product of the thickness of the layer of rolled aluminum (thickness: 11 m) and the value of the heat conductivity of 236 W/mK for pure aluminum results in an approximate value of 2.610.sup.3 W/K and thus indicates a high and therefore undesired heat transfer. Rolled aluminum films with thicknesses that large in the m-range are typically used as IR-reflectors in complex composite profiles, though for such purpose they are placed perpendicular to the main direction of heat transmission, as a result of which they are not able to adversely contribute to the heat conduction. Due to the high heat conductivity, films of that kind are not suitable to be use in heat insulating profiles substantially in parallel to the main direction of heat transmission.

Examples 1e and 1f: Measurements on a PET Film Metallized on One Side with Aluminum

[0210] This coated film may be used to produce a coating in accordance with the invention. For an approximation calculation of the , thicknesses product, a layer thickness of at most 15 m of polymer (PET film) with an estimated value of heat conductivity of 0.24 W/mK and a metallization layer of aluminum with a layer thickness of at most 40 nm and a heat conductivity of 236 W/mK (pure aluminum) is assumed.

[0211] The result of the result of the , thicknesses product of 1.310.sup.5 W/K or after inclusion of a thick bonding layer (plus 1.210.sup.5 W/K according to estimation: 40 m adhesive with 0.3 W/mK) of 2.510.sup.5 W/K is under 110.sup.4 W/K and thus indicates a desirably low heat transfer. Now when measuring on the side of the metal vapor deposition (Example 1e), the test for electrical conductivity results in a good conductivity with a specific surface resistance of <110.sup.5 Ohm and a value of about 3.010.sup.3 Ohm according to the accelerated test, respectively. The measurement of the PET side of the film (Example 1f) results in high electrical surface resistances, which are outside the measuring range of the accelerated test and according to the standard method DIN EN 61340-2-4 result in a specific surface resistance with a value of 1.2110.sup.15 Ohm.

TABLE-US-00001 TABLE 1 Properties of surfaces and determination of the electrical surface resistance Description Resistance Specific surface Thickness of the according to resistance [] of the measured multimeter according surface surface accelerated test to DIN Example Type layer layer (A = 1 cm) [] EN 61340-2-4 1a Insulating profile Homogeneous PA66 outside the 4.5 10.sup.13 insulbar composite 25% GF measuring REG material 1.8 rage (PA66GF25) mm >5 10.sup.7 1b Multi-layer 11-15 m PET film outside the 2.7 10.sup.12 laminate PET measuring with external rage layer and >5 10.sup.7 metallization thereunder 1c Multi-layer 40-80 nm Aluminum 7.8 10.sup.0 <1 10.sup.5 laminate (metal according vapor to Example deposition) 1b: external PET layer was preparatively removed and the metallization thereunder was exposed 1d Aluminum film 11-14 m Aluminum 2.2 10.sup.0 <1 10.sup.5 (rolled aluminum) 1e Film material: <40 nm Aluminum 3.0 10.sup.3 <1 10.sup.5 PET-single (metal layer with vapor metallization deposition) on one side, measurement on the side with metallization 1f Film material: 10-15 m PET film outside the 1.21 10.sup.15 PET-single measuring layer with rage metallization >5 10.sup.7 on one side, measurement on the PET film side

Example 2: Lacquering Results of the Powder Coating of Composite Profiles

Example 2a (Reference): Plastic-Aluminum Composite Profile, Constructed from Insulating Profiles of the Type Insulbar REG and Suitable Aluminum Half-Shells

[0212] The profile composites were dried before powder lacquering to a residual moisture in the profile of <0.3% by weight. It is determined that after lacquering and baking, the lacquer application on the plastic profile is incomplete and the lacquer coverage varies greatly. The lacquer coverage rate is thereby in the range of only about 40% to 55%.

Example 2b: Plastic-Aluminum Composite Profile, Constructed from Insulating Profiles of the Type Insulbar REG with a Coating of the Material A

[0213] An insulating profile was equipped with a material A as a coating in accordance with the invention. A composite profile was produced together with aluminum half-shells suitable therefor. The coating with the material A was configured such as to obtain a roll-in situation in accordance with FIG. 2A.

[0214] Composite profiles produced in such a manner were dried before powder lacquering to a residual moisture in the plastic profile of <0.3% by weight. It is determined that a uniform powder coverage is achieved in the powder application. After baking, a uniform homogeneous lacquer layer (lacquer coverage rate of 100%) on the plastic profile is obtained, which corresponds in surface structure and coverage largely to the lacquer layer formed on the aluminum shells of the composite profile. The coating is thus considered optimal.

Example 2c (Reference): Plastic-Aluminum Composite Profile, Constructed from Insulating Profiles of the Type Insulbar REG and Suitable Aluminum Half-Shells

[0215] The profile composites were not dried before powder lacquering and were processed with a residual moisture in the plastic profile of >1% by weight. It is determined that a full-area powder coverage is achieved in the powder application. After the lacquer-baking step, however, the differences in thickness of the lacquer layer are apparent in a negative way, which manifest themselves in brightness differences due to the black substrate shining through. Also negative in part is a very pronounced formation of bubbles in the region of the lacquer layer applied to the plastic profile. These bubbles are due to outgassing of residual moisture and constitute an undesirable defective appearance that is clearly visible to the naked eye.

Example 2d: Plastic-Aluminum Composite Profile, Constructed from Insulating Profiles of the Type Insulbar REG, are Equipped with Material a and Aluminum Half-Shells Suitable Therefor

[0216] The coating was configured such that a roll-in situation according to FIG. 2A was produced. The composite profiles were not dried before powder lacquering and were processed with a residual moisture in the plastic profile of >1% by weight. It is determined that a uniform powder coverage with a rate of 100% is achieved in the powder application. After baking, a uniform homogeneous lacquer layer on the plastic profile is obtained, which corresponds in surface structure and coverage largely to the lacquer layer on the aluminum shells of the composite profile. The coating is thus optimal.

Example 2e (Reference): Plastic-Aluminum Composite Profile, Constructed from Insulating Profiles of the Type Insulbar LO18 and Suitable Aluminum Half-Shells

[0217] The composite profile was dried before powder lacquering to a residual moisture in the plastic profile of <0.3% by weight. It is determined that after lacquering and baking, the lacquer application on the plastic profile is incomplete and the rate of average lacquer coverage is in the range of only about 50%.

Example 2f: Plastic-Aluminum Composite Profile, Constructed from Insulating Profiles of the Type Insulbar LO18, which are Equipped According to the Invention with Material B, as Well as Aluminum Half-Shells Suitable Therefor

[0218] The composite profile that is obtained corresponds to the roll-in situation according to FIG. 2C. The layer structure of material B corresponds to the layer structure according to FIG. 4A. The composite profiles were dried before powder lacquering to a residual moisture in the plastic profile of <0.3% by weight. It is determined that a uniform powder coverage is achieved in the powder application. After baking, a uniform homogeneous lacquer layer (lacquer coverage rate of 100%) on the plastic profile is obtained, which corresponds in surface structure and coverage largely to the lacquer layer on the aluminum shells of the composite profile. The coating is thus optimal.