Headlight restoration kit

Abstract

A method and kit for restoration of a plastic headlight surface including the steps of conditioning a headlight surface by wet sanding with 600 grit sandpaper effective to remove a laminate coating, wiping the headlight surface with a lint free towel, cleaning the headlight surface with an alcohol treated towel, coating the headlight surface with an ultra violet light curable restoration formulation comprising aliphatic urethane acrylate in the range of 25% to 60%, a photoinitiator in the range of 1% to 5%, N-butyl acetate in the range of 5% to 25%, Toluene in the range of 3% to 15%, a Methyl isobutyl ketone in the range of 3% to 15%, a light stabilizer in the range of 1% to 5%, and includes a flow agent; and exposing the coated headlight surface to an ultra-violet light for about 2 minutes. In the preferred embodiment, the formulation includes a hydrocarbon propellant and is applied from a spray can.

Claims

1. A method of restoring a plastic headlight surface comprising the steps of: conditioning a headlight surface by wet sanding; wiping said headlight surface after wet sanding with a lint free towel to remove sanding debris; cleaning said headlight surface with an alcohol treated towel; coating said headlight surface with a curable aliphatic urethane restoration formulation, said curable aliphatic urethane restoration formulation comprising an aliphatic urethane acrylate in the range of 25% to 60%,a photo initiator in the range of 1% to 5%, n-butyl acetate in the range of 5% to 25%, toluene in the range of 3% to 15%, methyl isobutyl ketone in the range of 3% to 15% and a light stabilizer in the range of 1% to 5%; and exposing said headlight surface to a ultra-violet light for curing of the coating on said headlight surface.

2. The method of restoring a plastic headlight surface according to claim 1 wherein about 600 grit sandpaper is used for wet sanding.

3. The method of restoring a plastic headlight surface according to claim 1 wherein said curable aliphatic urethane restoration formulation includes a flow agent allowing placement of said restoration formulation in a sprayer, said sprayer having a hydrocarbon propellant for use in applying a coating of said restoration formulation on a headlight surface.

4. The method of restoring a plastic headlight surface according to claim 1 wherein said step of conditioning is to remove a contaminated or oxidized layer surface wherein said contaminated or oxidized layer surface is wet sanded until the headlight surface is free of contamination or oxidation.

5. The method of restoring a plastic headlight surface according to claim 1 wherein said step of conditioning is performed to a laminate coating on the headlight surface.

6. The method of restoring a plastic headlight surface according to claim 1 wherein said step of conditioning is to remove a laminate coating by wet sanding in only a vertical pattern and a horizontal pattern.

7. The method of restoring a plastic headlight surface according to claim 1 wherein said headlight surface is exposed to a ultra-violet light for about 2 minutes for curing the coating placed on the headlight surface.

Description

DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a flow chart illustrating the process of headlight restoration.

DETAILED DESCRIPTION OF THE INVENTION

(2) The following is a detailed description of an example embodiment of the invention depicted in the accompanying drawing. The example embodiment is in such detail as to clearly communicate the invention. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments wherein the instant formulation may be used on new plastic as well as plastic in need of restoration, as well as cover modifications, equivalents, and alternatives falling within the spirit and scope of this specification and appended claims. The detailed description below is designed to make such embodiments obvious to one skilled in the art.

(3) The restoration kit of the instant invention requires the plastic lens of the headlight be prepared for receipt of a restoration formulation (10). The plastic headlight surface is prepared by first conditioning the headlight surface by removing the contaminated laminate coating, or removing a contaminated and possibly oxidized surface by wet sanding (20). The wet sanding is performed with 600 grit sanding paper with sanding movement in a vertical and horizontal pattern. The sanding paper is kept wet at all times and circular motions are not recommended. A dual action sander may be used with experience, but an orbital type sander is not recommended. The sanding process is performed using medium pressure until the oxidized laminate is removed. It is noted that an original laminate coating turns amber with age; the sanding will remove the old, damaged laminate. It should further be noted that the use of various grades of sandpaper to accomplish the laminate removal is possible, but does not improve the efficiency of the instant invention or the resulting quality. For instance, progression of paper grades from 220 to 400 to 600 to 800 can be used, but the time spent in smoothing out the surface with the finer grades does not increase the quality of results. Further, while a surface sanded with 2000 grit sandpaper is smoother than 600 grit sandpaper, the restoration formulation of the instant invention does not require a smoother surface than that offered by 600 grit sandpaper. The surface structure left from use of the 600 grit sandpaper provides a more suitable attachment surface for the formulation. The wet sanding continues until the laminate coating is removed (30).

(4) Water is preferably used to clear the surface from sanding residual. If the wet sanding does not remove the laminate coating (40) the process is continued until the laminate is removed. If the laminate coating is removed (50) then a lint free towel is used to dry the residual free surface and assure that the surface is free of dirt, grime and sanding residual (60). The lint free cloth assures that no particles of lint become attached to the lens. The lens will appear cloudy due to the microscopic scratches caused during the coating removal, however, the restoration formulation will fill in the imperfections caused during the sanding procedure.

(5) Once the lens has been dried, an alcohol treated towel is used to assure all contaminates have been removed (70). In addition, the alcohol treated towel can be used to verify removal of any residues and surface contaminates. The headlight surface is reinspected at this point (80), and if the surface indicates any laminate remains, the wet sanding process is repeated (90), followed by the rinse, dry and alcohol towel which help reveal if any laminate remains.

(6) If the alcohol leaves the surface with a dull finish, but free of oxidation, the laminate has been removed (100) and the headlight surface is then coated with a restoration formula having an ultra violet light curable formulation. Aliphatic urethane acrylate in the range of 25% to 60% and a photoinitiator in the range of 1% to 5% provide a base. N-butyl acetate in the range of 5% to 25%, Toluene in the range of 3% to 15% and Methyl isobutyl ketone in the range of 3% to 15% result in a coating that will not degrade over time. A light stabilizer in the range of 1% to 5% and a flow agent allows for placement of the formulation in a spray container using a hydrocarbon propellant.

(7) In application, a light tack coat and then a final wet coat provides the proper coating. As the formulation is curable upon exposure to ultraviolet radiation, the coatings need to be applied out of direct sunlight. Application of the formulation in a spray pattern requires the spray be applied perpendicular to the lens surface. With a lens that has curved ends or edges, the spray pattern should follow the curvature to prevent angling of the spray pattern. A very light spray patter, tack coat, is applied to the lens (110). After about 30 seconds, a second coating is sprayed from a distance of about five inches from the surface of the lens forming a wet coat application (120).

(8) The coating is then curable by use of a UV-A light (130) which is positioned approximately 3-5 inches from the lens surface for about 2 minutes. Alternatively, the coating can be cured by placement in direct sunlight. If the coating is not clear and smooth, the application process was likely flawed. Dry or cure the lens in the direct rays of the sun or use the UV-A tripod and then repeat the process after removing (150) the new lens coating. If the coating is clear and smooth (160), the vehicle can be driven after exposure to the UV light source and the lens can then be commercially washed.

(9) TestLong Term Efficacy

(10) Q-LABORATORIES INC., was retained using test method SAE J2527 2004-02 (nationally mandated to verify longevity on outside of vehicles) to determine long term efficacy of the coating.

(11) Number of Specimens:

(12) Specimen ID 1. Toyota treated 2. Ford treated 3. Chevrolet treated 4. G6 treated 5. Lexus treated The test used accelerated weathering with Zenon Arc Lamps. The test exposed the coating of the instant invention for 2500 KJ/M2 (2500 kilojoules). Results reported on the headlamps removed from older cars no longer in service.

(13) Q-LAB Report The standard scale used to evaluate observable changes is a 1-10. 1-2 Change is so minimal that it cannot be detected by the naked eye, only by a special measuring device 3-4 Minimal change that could only be recognized by a trained eye 5 Change that can be slightly noticed 6-7 A moderate change that is growing 8-10 A pronounced change to severe Zenon Accelerated Weathering. After accelerated weathering in the Q-Sun Xenon Test Chamber for 2500 KJ/M2, it was observed that the average difference noted in the five vehicle lenses having been restored by use of the instant invention was in the range of 0.98 to 2.31, a change that could not be detected by the human eye. The test supports long term efficacy of the coating. Test Date: 30 Jun. 2010 Duration 1875 kJ/m.sup.2 Exposure Xenon Arc lamps, 0.55 W/m.sup.2, DaylightBIB filters

(14) TABLE-US-00001 Specimen ID Original Present Difference 1 - Toyota 6.11 8.42 2.31 2 - Ford 4.11 5.37 1.26 3 - Chevrolet 7.59 8.57 0.98 4 - G6 7.56 9.62 2.06 5 - Lexus 3.44 5.05 1.61

EXAMPLE

(15) UV Degradation over time. Analysis of a particular case showed a 3,000 candela reading on low beam and 7,000 candela reading on high beam. Degradation of the hard coat on the polycarbonate (PC) is blocking the transmission of light from the internal headlamp bulb. When the headlight lens was refinished with the proper sealer technology, the headlight lens survey showed 7,000 candela reading on low beam and 17,000 candela reading on high beam.

(16) TABLE-US-00002 Appln 3M BG VEW DVP HRD Lifetime Warranty (Lab YES NO NO NO NO NO Test) Spray on Application YES NO NO NO NO YES Quick and Easy to Apply YES NO NO NO NO YES Requires Wax Sealer NO N/A N/A YES YES N/A Periodically Temperature Sensitive NO N/A N/A YES YES NO Application Even Coverage on Sealer YES N/A NO NO NO YES Lab Test SAE J2527 YES N/A N/A NO N/A NO 2004-02 Cures with UVA YES N/A NO NO NO NO One Time Permanent YES NO NO NO NO NO Solution Chemicals for pretreatment NO YES UKN NO YES NO

(17) Headlight restoration products on the market include 3M Headlight Lens Restoration which makes no claims as to the longevity of the technology, typically lasts only 5-10 months. 3M has no warranty and the lens clarity is temporary; clear for a few months then cloudiness returns. The product requires eleven steps and 30-40 minutes to complete.

(18) BG's is used by a number of automobile dealers that also use BG's care and appearance products. BG has a five step process that takes 20-30 minutes to complete. The process uses power equipment to sand, buff and polish, and requires a hair dryer after the sealer is smeared on to improve final effect. Substantial buffing and polishing after removal of the damaged laminate is required. BG's warranty is described as will last as long as original finish.

(19) Crystal View is an earlier generation headlight restoration technology which is very labor intensive, uses a smear on or wipe on process with their sealer application that can lead to streaks or overlap on the finish. The product is sensitive to temperature at the time of application and can cure too quickly compounding the possibility of mistakes. The product does not protect against ultra-violet light.

(20) Dvelup Headlight Restoration Product has multiple steps including three grades of sandpaper, use of chemical and compounds to prepare lens for sealant, reflective of a thin sealant. Sealant is a foam brush smear on application. Drying time is based on temperature and may take up to 40 minutes if the temperature is between 20 and 50 degrees. The application of wax may be needed at least twice a year to protect against damage. Dvelup offers no factor warranty, but recommends that the distributor decides what warranty, if any, should be offered.

(21) HeadlightRenewDoctor employs sandpaper and water for removal of damaged laminate process. A sealer is employed that cures without UVA, such as a clear coat.

(22) TABLE-US-00003 Appln MEG MOC PTX RNX SYM WYN Lifetime Warranty YES NO NO NO NO NO YES (Lab Test) Spray on YES NO NO NO YES NO NO Application Quick and Easy to YES YES NO NO NO NO NO Apply Requires Wax NO N/A N/A N/A YES YES NO Sealer Periodically Temperature NO N/A N/A N/A UKN NO NO Sensitive Application Even Coverage on YES N/A NO NO NO YES NO Sealer Lab Test SAE J2527 YES N/A NO NO NO NO NO 2004-02 Cures with UVA YES N/A NO NO NO NO NO One Time YES NO NO NO NO NO NO Permanent Solution Chemicals for NO NO NO YES YES YES YES pretreatment

(23) Meguiars Headlight Restoration employs an abrasive compound applied by a polishing pad, followed with a microfiber towel. No lens sealer is provided.

(24) MOC Headlight Restoration uses a thin lens sealer with various grades of wet sandpaper to remove damaged laminate. The process takes 40 minutes to complete, and a thin sealer is smeared on by foam applicator.

(25) Permatex Headlight Restoration Products use a very thin sealer, requiring 4 different types of abrasive sheets to remove the damaged lens coating and scratches. The process takes 40 minutes using a single 600 grit. A smear on foam pad-coating typically lasts up to one year or less according to reports from the field.

(26) Rain-X Headlight Restoration uses a chemical to rinse the headlights. Three pads with lubricant are used in the removal process with buffing until clarity is observed.

(27) Symtech Headlight Restoration is first prepared by use of 1500 and 2000 grit sandpaper. A polishing compound is used to remove scratches from earlier removal of damaged laminate. A sealer transfers from paper to a very thin film. Periodic waxing is required to maintain appearance.

(28) Wynn's Headlight Restorer takes about 30 minutes to prepare and requires sandpaper with multiple grades of grit. An abrasive paste is employed after sanding. Polishing of lenses is required and a foam brush is used to smear on a sealant.

(29) All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.

(30) It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.

(31) One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.