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WO2001042374A1 - Water-based ceramic paint darkened with silicate hydrates - Google Patents

Water-based ceramic paint darkened with silicate hydrates Download PDF

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Publication number
WO2001042374A1
WO2001042374A1 PCT/GB2000/004377 GB0004377W WO0142374A1 WO 2001042374 A1 WO2001042374 A1 WO 2001042374A1 GB 0004377 W GB0004377 W GB 0004377W WO 0142374 A1 WO0142374 A1 WO 0142374A1
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WO
WIPO (PCT)
Prior art keywords
water
composition
weight percent
forming
paint
Prior art date
Application number
PCT/GB2000/004377
Other languages
French (fr)
Inventor
Claude Franklin Mason
Original Assignee
Visteon Global Technologies, Inc
Gemmell, Peter, Alan
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Visteon Global Technologies, Inc, Gemmell, Peter, Alan filed Critical Visteon Global Technologies, Inc
Publication of WO2001042374A1 publication Critical patent/WO2001042374A1/en

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Classifications

    • CCHEMISTRY; METALLURGY
    • C03GLASS; MINERAL OR SLAG WOOL
    • C03CCHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C17/00Surface treatment of glass, not in the form of fibres or filaments, by coating
    • C03C17/006Surface treatment of glass, not in the form of fibres or filaments, by coating with materials of composite character
    • C03C17/008Surface treatment of glass, not in the form of fibres or filaments, by coating with materials of composite character comprising a mixture of materials covered by two or more of the groups C03C17/02, C03C17/06, C03C17/22 and C03C17/28
    • CCHEMISTRY; METALLURGY
    • C03GLASS; MINERAL OR SLAG WOOL
    • C03CCHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C17/00Surface treatment of glass, not in the form of fibres or filaments, by coating
    • C03C17/02Surface treatment of glass, not in the form of fibres or filaments, by coating with glass
    • C03C17/04Surface treatment of glass, not in the form of fibres or filaments, by coating with glass by fritting glass powder
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D1/00Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
    • C09D1/02Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances alkali metal silicates

Definitions

  • This invention is directed to an alkali metal silicate water-based paint composition especially useful for providing a dark-colored paint field on soda-lime-silica glass sheets through the use of silicate hydrates.
  • paint compositions are known for use on automotive and architectural glass. Such paints are used, for example, to form opaque borders around the peripheral marginal surfaces of glazings used as windshields, sidelites, and backlites of motor vehicles. These borders are used to obstruct from view attachment means for the glazings and protect adhesives which might be used from exposure to light which could degrade them.
  • these compositions are ceramic compositions formed from a mixture of metal oxides in an organic (oil based) vehicle like mineral oil.
  • the opaque peripheral marginal paint bands fired onto automotive glazings are generally black provided by colorant oxides like chrome oxide, cobalt oxide and nickel oxide.
  • colorant oxides like chrome oxide, cobalt oxide and nickel oxide.
  • more desirable water-based paints have been developed for use in place of such organic vehicle paints.
  • One such paint is disclosed in US patent 5,698,026 commonly assigned herewith which advantageously is curable at relatively low temperatures compared to the relatively high temperatures generally required for ceramic/organic vehicle paint curing. Subjecting the glass to high temperatures to cure the paint can impart undesirable optical distortions into the glass sheets.
  • the '026 paint is a soda-lime silicate based paint which uses metal oxide pigment to color the glass.
  • One of the drawbacks of the paint is that the color of the water based silicate paint is not as dark as the oil based paint having the same amount of metal oxide pigment. If these two different paints are used in the same automotive vehicle on different glazings, the color should be formulated to appear the same. And merely adding more metal oxide colorant to the water based silicate paint in an attempt to darken the color suitably is not effective to do so. Hence, it is necessary to find another way to darken the color of the silicate paint when desired without negatively affecting the excellent properties of the paint .
  • the invention disclosed herein is a water-based paint composition particularly useful as to provide a dark coating on soda-lime-silica glass.
  • the composition comprises :
  • water-soluble silicate forming 5 to 50 weight percent of the composition of which up to 40 weight percent is sodium silicate and the balance is water-soluble hydrated alkali metal silicate;
  • water-soluble base in an amount sufficient to provide the composition with a pH of at least about 12;
  • finely divided metal oxide powder being selected from the group consisting of oxides of copper, iron, nickel, cobalt and mixtures thereof forming 20 to 40 weight percent of the composition and having a particle size less than 7 microns;
  • glass frit powder melting below 1300°F and forming 15 to 40 weight percent of the composition and having a particle size, on average, less than 10 microns; optionally,
  • particles of glass forming 0 to 25% weight percent of the composition and having a diameter, on average, up to 20 microns and comprising soda-lime-silica glass having a melting point of at least about 1700°F; and (vii) zinc oxide forming 0 to 10 weight percent of the composition.
  • the composition comprises small amounts of aluminum hydroxide.
  • the invention in another aspect, is a preferred process of making the above disclosed water-based paint which comprises (a) combining powders of the metal oxide colorants, low melting frit, any soda-lime-silica glass, and any zinc oxide, (b) heating the mixture to melt the powders together, cooling the melt and grinding the resultant material to form powder of desired particle size. These powders is then mixed with the silicate dissolved in water and the pH of the liquid mixture adjusted using the hydroxide to form the paint. According to still another aspect of the invention, it is a cured coating of the paint on a glass sheet .
  • the invention composition is a water-based paint useful as a coating on glass, such as for the "black out” area around the periphery of a windshield.
  • the glass paint components comprise, as disclosed in detail above, alkali metal silicate including hydrated silicate, water, water- soluble base, metal oxide powder like copper oxide, low- melting glass frit powder, and optionally, one or both of high-melting glass particles comprising soda-lime-silica glass and zinc oxide.
  • the metal oxide powder e.g., copper oxide, contributes to give the paint its black to gray color. As pointed out above, it may be desired to make the paint darker to match other paint on the glazings of the vehicle or merely for aesthetic appearance.
  • Water-soluble silicates form between about 5 and 50 weight percent of the composition of this invention. Of those composition silicates up to 40 weight percent are sodium silicates and the balance is hydrated alkali metal silicates. More preferably, the paint composition comprises between about 0 and 10 weight percent sodium silicates, as “sodium silicates” is used herein it means not-hydrated alkali metal silicates, in contrast to alkali metal silicate hydrate. Most preferably about 5-10 weight percent sodium silicates are used. As used herein "weight percent of the composition” meaning a fraction of the total weight of the paint composition. These sodium silicates may comprise a single sodium silicate or a mixture of such silicates.
  • Water-soluble sodium silicates useful in this invention composition can be represented by the formula Si0 2 :Na 2 0, wherein the mole ratio therein of the two oxides is from about 2:1 to about 4:1.
  • water-soluble potassium silicates of similar formula may also be included in the composition. When they are included, they are generally present in minor amounts, preferably less than 5 percent by weight, generally between about 5 and 10 weight percent of the composition.
  • hydrated alkali metal silicates which comprise all of part of the 5-50 weight percent of the composition silicates disclosed above.
  • these alkali metal silicate hydrates comprise about 10 to 30 weight percent of the paint composition.
  • Hydrated alkali metal silicate can be any such material, the pentahydrate form being the most commonly available.
  • the hexahydrate, octahydrate, and nonahydrate forms are well known and commonly available. All such materials have melting points below 100°C as is desired.
  • Sodium forms such as sodium meta silicate pentahydrate are useful as well as the potassium forms of these hydrates.
  • the paint composition in addition to the alkali metal silicate hydrates, some non- hydrated forms of the silicates like sodium silicate because the non-hydrated sodium silicate forms cured paints with improved durability. If desired, however, all of the silicates of the paint composition may be alkali metal silicate hydrates.
  • Water which is included in an amount between about 10 and 30 weight percent of the total paint composition, is preferably included in an amount between about 10 and 20 weight percent.
  • the paint optimally it is formulated in two parts which are then combined before application on the surface, of e.g., glass. One of the two parts is made by dissolving the silicates in the water.
  • the composition further comprises finely divided metal oxide pigment selected from copper oxide, iron oxide, nickel oxide, cobalt oxide and mixtures thereof, with the inclusion of copper oxide being preferred.
  • This pigment gives the paint a black color and forms 20 to 40 weight percent of the composition, preferably between about 20 to 35 weight percent of the composition.
  • the finely divided powder pigment has a particle size (diameter) on average less than about 7 microns, preferably being between about 3 and 7 microns, most preferably being about 5 microns. These compositions would vary in color from black to dark gray, depending on the mixture and percentages of the metal oxides. Copper oxide, which is preferred, provides a black paint composition. It is undesirable to use chromium oxide in the paint composition since it interferes with the adhesion of the paint to the glass.
  • the paint also includes a glass frit powder which is a low-melting glass material which melts below about 1300°F. Optimally it is included in the water based paint composition in an amount comprising 15-40 weight percent, more preferably being between about 20 and 40 weight percent, most preferably being between about 20 and 35 weight percent of the present invention blackish paint composition.
  • the low-melting glass frit is used in a powder form, the particle diameter being on average less than about 10 microns, preferably being between about 3 and 7 microns, most preferably being on average about 7 microns.
  • Exemplary of preferred glass frit materials useful in the present composition are silicates of metals such as zinc, boron, bismuth, titanium, zirconium, and aluminum and mixtures thereof, e.g., titanium-silicate glass, zinc boro-silicate glass and bismuth boro-silicate glass.
  • metals such as zinc, boron, bismuth, titanium, zirconium, and aluminum and mixtures thereof, e.g., titanium-silicate glass, zinc boro-silicate glass and bismuth boro-silicate glass.
  • Many such glass frits are readily commercially available as from General Colors Co. and O. Hommell Co. Still other glass frits which may be employed in the present invention will be apparent to those skilled in the art in view of the present disclosure.
  • the low-melting glass frit serves to improve paint adhesion to the glass, to PVB which may be used in a windshield laminate, and urethane which is often used to seal and attach the glass in an automotive vehicle.
  • PVB is used within laminated windshields and urethane sealants are used between the glass and the car body.
  • the paint composition optionally includes particles of soda-lime- silica glass which is a high-melting glass frit.
  • This component contributes to improved temperature stability of the paint and adhesion to the glass on which it is applied.
  • the particles are made of any soda-lime-silica glass, this type of glass being well known in the glass industry.
  • Soda-lime-silica glass used in the automotive and architectural industries, is commonly made by the float glass process. It is generally characterized by the following basic composition, the amounts of the components being based on a weight percentage of the total glass composition: silicon dioxide 68-75; aluminum oxide 0-5; calcium oxide 5-15; magnesium oxide 0-10; sodium oxide 10- 18; and potassium oxide 0-5.
  • the calcium oxide + magnesium oxide is 6-15%, and sodium oxide + potassium oxide is 10-20%.
  • Such glasses can include colorants like iron oxide, cobalt oxide, or. copper oxide to name a few.
  • UV absorbers like titanium oxide or cerium oxide are incorporated to improve the optical properties.
  • Soda-lime-silica glasses, either with or without such colorants or other additives may be used in the present invention paint composition.
  • glass particles included in the paint composition would be similar or identical to the glass on which the paint will be applied, however, such is not necessary.
  • the use of a particular soda-lime-silica glass is not critical to the present invention.
  • the glass particles may be in powder or spherical form. Generally, the diameter of the particles is, on average, up to 20 microns, being preferably 3 to 15 microns. More preferably, the particles have a diameter in the range of about 5 to 7 microns .
  • the soda-lime-silica particles are optionally included in the paint composition in an amount up to 25 weight percent based on total weight of the paint composition.
  • the amount of such high-melting glass particles in the water-based paint is up to 20 wt . percent, optimally being up to 10.
  • These particles may be obtained by grinding the glass to a desired diameter or obtained commercially.
  • Spherical particles are most desirable when the paint is to be applied by screen printing, since they are less abrasive to the screen.
  • Spherical particles are commercially available, for example, from Cataphote Inc., under the name Glas-Shot tm . In the case of spherical particles the size may be 5 to 20 microns or even smaller since they optimally suitable for use, however smaller sizes are not as readily commercially available .
  • the chromium-free paint may further include an adhesion promoter: zinc oxide.
  • This adhesion promoter like the low-melting glass frit, promotes the adhesion of the paint to the glass. And, in addition, when the paint is used in contact with vinyl as in a laminated windshield, these adhesion promoters also promote the adhesion of the vinyl to the glass as described below.
  • zinc oxide When zinc oxide is included in the composition, it comprises generally about up to 10 weight percent, preferably being 2 to 10 weight percent, and more preferably between about 3 and 6 weight percent. Optimally, when included, it comprises between about 4 and 6 weight percent based on the weight of the composition.
  • the zinc oxide is preferred to be provided in the paint composition in a particle size of between about 2 and 3 microns on average, however particle size is not critical.
  • the water-soluble base is employed to provide the paint composition with a pH of at least about 12, preferably being above 12.5, more preferably about 13.5 or above.
  • the pH is required to be on the basic side as is indicated by the required pH . Providing the composition with this pH is necessary to impart desirable shelf life to the paint.
  • Embodiments of invention paints with a pH above about 13, for example, have been found to be shelf stable for at least 3 months.
  • water-soluble bases which may be employed include but are not limited to sodium hydroxide and potassium hydroxide, with sodium hydroxide being preferred.
  • the amount of base employed is dependent, e.g., on the particular base and concentration employed.
  • a 2N sodium hydroxide base is generally included in about 2 to 10 weight percent of the composition, more preferably in about 3 to 8 weight percent, and most optimally, in about 3 to 6 weight percent.
  • Optimal amounts and types of bases which may be employed would be apparent to those skilled in the art in view of the present disclosure.
  • the first part is the silicates dissolved in the water.
  • the second part is formed of the other solid materials discussed above: the metal oxide colorants, the low melting glass frit, and soda-lime-silica and/or zinc oxide when used. To form this second part, these solid materials would be mixed together and heated to melt them together. After the melt is cooled, it is ground to a powder of desired particle size, generally of less than 10 microns, preferably, 5 to 7 microns. Then the first part which is a liquid and the second part which is a powder are combined to form a liquid paint mixture and the pH of the liquid mixture adjusted with the water-soluble base.
  • Still another optional, but desirable, component included in the black paint composition of this invention is a surfactant.
  • Surfactants are well known materials and often added to paints to improve the wetting characteristics of the liquid paint to the substrate to which it is applied. Exemplary of one such material is "FC-171" made by 3M Company. Still other surfactants are known to those skilled in the art. Desirably, it forms about 0.1 to 1.0 weight percent of the paint composition, more preferably about 0.25 to 0.5 weight percent. The surfactant would be generally added to the final paint composition.
  • Aluminum hydroxide which is preferably included in the composition in up to about 5% by weight of the composition. It is generally added to the paint as aluminum hydroxide hydrate and has been found to increase the shelf life of the paint and may increase the adhesion of the paint to the glass sheet. In forming the paint composition, it would generally be added to the final paint composition.
  • the components may be added together and then ball milled until a substantially uniform mixture of components is obtained. This milling may also be carried out to provide the desired particle size of the components, for example the glass particles and optional components like the glass frit, if they are initially present in particles sizes which are larger than desired in the final paint.
  • a more preferred method for making the paint composition involves the two-part technique described above. By mixing the powders together and then melting them together, the final ground powder is a well mixed dispersion of all solids. This melting, cooling and subsequent grinding breaks up any agglomerates and provides a substantially uniform mixture of the solids. This solids mixture is then incorporated with the first part (dissolved silicates) with mixing to form the paint.
  • the paint composition made this way was found to be easily painted onto glass surfaces by conventional techniques such as silk screenings. This mixing is generally carried out at room temperature.
  • the base is preferably added after mixing of the two parts, but may also be added into the first part. Ideally, however, I prefer to add base just before the paint is to be used.
  • the subject invention composition After making the subject invention composition, it may be applied to a substrate, particularly a glass substrate in the case of automotive "black-out", by any technique.
  • the glass sheet may be prepared from any type of glass generally known in the art of glass making. Typical glass sheets contemplated for use according to the present invention are soda-lime-silica automotive and architectural glazings, generally produced by the well- known float glass process.
  • the paint is applied as a uniform layer to a surface of the glass sheet in a predetermined pattern by any paint application method, e.g., screen printing wherein the paint is spread across the screen by a squeegee to force the paint through the pattern onto the glass sheet.
  • any paint application method e.g., screen printing wherein the paint is spread across the screen by a squeegee to force the paint through the pattern onto the glass sheet.
  • the moist environment is maintained about 80+5% rh with the present invention preferred paint compositions. Maintaining this moist environment allows for prolonged use of the paint application screen system by maintaining the moisture content of the paint at a desirable viscosity for application.
  • This environment may be optimally provided, e.g., by the invention described in U.S. Patent 5,509,964 to Boaz and
  • the predetermined pattern in which the paint may be applied to a glass sheet may comprise, for example, an opaque concealment band positioned on a peripheral marginal surface of an automotive glazing.
  • concealment bands are well known in the art of automotive glazings as useful for preventing the solar radiation induced degradation of adhesives used to mount the glazings in a vehicle opening, and for concealing attachment hardware and structural components which lie below the edges of the glazings.
  • the band generally extends to the edges of the glazings, and has a width sufficient to conceal the underlying adhesive and structural components, but which is sufficiently narrow to provide maximum vision to occupants of the vehicle.
  • other predetermined patterns may be utilized where applying various paint fields to glass surfaces, depending upon the ultimate purpose for the cured paint field.
  • the coating is preferably provided in a thickness of about 12-16 microns.
  • the coating may be applied in any thickness, however, the optimal thickness being determined by the particular application desired.
  • the curable compositions of the invention after being applied to a substrate, are readily cured by baking at an elevated temperature for a time sufficient to drive off the water which cures the coating.
  • This step may be carried at any temperature, but desirably at a temperature below the softening point of the glass. Since this water vaporization and curing can be preferably carried out at moderate temperatures, e.g., below about 400°C, even between about 100°C and 200°C, the painted glass is not subjected to softening and hence is prevented from being distorted during the moderate temperature.
  • Paint compositions applied to glass sheets are generally first cured in order to make the painted glass available for handling for further processing, i.e., bending of the painted glass sheet into a desired final shape. Heating glass to temperatures above the softening point of the glass to cure organic vehicle paints provides the glass with an opportunity to pick up distortions. Subsequent bending of the painted glass, in a second firing, again at these high temperatures provides a second opportunity for distortions to be incorporated into the glass product.
  • the present invention paint because it can cure at relatively low temperatures below the softening point of the glass, desirably minimizes the opportunity for distortion to be incorporated into the glass product.
  • This drying and curing of the water-based black paint composition may be carried out by any means.
  • Two particularly preferred means comprise subjecting the paint applied to the glass to Infra Red (IR) radiation or microwave radiation as in a microwave oven.
  • IR Infra Red
  • microwave radiation as in a microwave oven.
  • the latter is most particularly preferred because it may be provided as a compact unit of relatively small size, it consumes less energy and generally requires less maintenance.
  • the present invention moderate temperature curable compositions are of considerable advantage in that they provide for significant energy savings in comparison to compositions which require significantly elevated temperatures for curing.
  • the substrate when the substrate is glass, optical distortions can be incorporated into the glass sheet when it is exposed to significantly elevated temperatures as required to cure conventional organic vehicle glass coatings.
  • the present invention composition overcomes this disadvantage of prior art coatings which require elevated temperatures for curing the paint. While, as described above, the paint finds particular usefulness on glass, it may also be used to paint other substrates, including, e.g., metal or plastic .
  • coated automotive glass will subsequently be subjected to shaping which involves subjecting the glass to high temperatures of the order of 1150°F or more, which can be 1250°F or more if the glass is tempered. This will allow the coating to further cure, although such is not required to provide a durable and adherent coating on a substrate.
  • Ground glass 0 Soda-lime-silica 7 ⁇ diameter
  • the black paint compositions above, embodiments of the present invention were made in two parts as described above.
  • the powders were heated and calcined at 975 degrees F for 6 hrs. and then cooled and ground into a powder mixture having a particle size of about 7 microns.
  • the two parts were then combined and mixed for 6 minutes, and the mixture adjusted with the hydroxide and then surfactant was added.
  • the paint had a pH of about 13.5.
  • the paint was applied by screen printing to glass (soda- lime-silica) sheets to a thickness of 16 microns and cured in an oven which heats the glass to over 550°C and fully cures the paint.
  • the paint had a dark black color and developed rapidly during the heating process.

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Abstract

The invention is directed to a dark colored water-based paint composition comprising water soluble alkali metal silicate of which at least a part are silicate hydrates, water, water-soluble base, metal oxide pigment, and optionally any of a low-melting glass frit, soda-lime-silica glass particles, and/or zinc oxide. It may further optionally include surfactants and aluminum hydroxide. The paint composition is particularly useful as a black-out paint on automotive glazings.

Description

WATER-BASED CERAMIC PAINT DARKENED WITH SILICATE HYDRATES
Reference is made to related U.S. application Serial No. 09/220027 filed December 23, 1998 entitled "High Solids Water-Based Ceramic Paint" commonly assigned herewith.
Field of the Invention
This invention is directed to an alkali metal silicate water-based paint composition especially useful for providing a dark-colored paint field on soda-lime-silica glass sheets through the use of silicate hydrates.
Background of the Invention
Various paint compositions are known for use on automotive and architectural glass. Such paints are used, for example, to form opaque borders around the peripheral marginal surfaces of glazings used as windshields, sidelites, and backlites of motor vehicles. These borders are used to obstruct from view attachment means for the glazings and protect adhesives which might be used from exposure to light which could degrade them.
Generally these compositions are ceramic compositions formed from a mixture of metal oxides in an organic (oil based) vehicle like mineral oil. The opaque peripheral marginal paint bands fired onto automotive glazings are generally black provided by colorant oxides like chrome oxide, cobalt oxide and nickel oxide. In view of environmental and commercial considerations, more desirable water-based paints have been developed for use in place of such organic vehicle paints. One such paint is disclosed in US patent 5,698,026 commonly assigned herewith which advantageously is curable at relatively low temperatures compared to the relatively high temperatures generally required for ceramic/organic vehicle paint curing. Subjecting the glass to high temperatures to cure the paint can impart undesirable optical distortions into the glass sheets. More particularly, the '026 paint is a soda-lime silicate based paint which uses metal oxide pigment to color the glass. One of the drawbacks of the paint is that the color of the water based silicate paint is not as dark as the oil based paint having the same amount of metal oxide pigment. If these two different paints are used in the same automotive vehicle on different glazings, the color should be formulated to appear the same. And merely adding more metal oxide colorant to the water based silicate paint in an attempt to darken the color suitably is not effective to do so. Hence, it is necessary to find another way to darken the color of the silicate paint when desired without negatively affecting the excellent properties of the paint .
It is an object of the present composition to provide a water-based paint composition which is capable of displaying a dark color. This is accomplished by the present invention paint which is curable at relatively low temperatures and which exhibits excellent durability. Disclosure of the Invention
The invention disclosed herein is a water-based paint composition particularly useful as to provide a dark coating on soda-lime-silica glass. The composition comprises :
(i) water-soluble silicate forming 5 to 50 weight percent of the composition of which up to 40 weight percent is sodium silicate and the balance is water-soluble hydrated alkali metal silicate; (ii) water forming 10 to 30 weight percent of the composition; (iii) water-soluble base in an amount sufficient to provide the composition with a pH of at least about 12;
(iv) finely divided metal oxide powder being selected from the group consisting of oxides of copper, iron, nickel, cobalt and mixtures thereof forming 20 to 40 weight percent of the composition and having a particle size less than 7 microns;
(v) glass frit powder melting below 1300°F and forming 15 to 40 weight percent of the composition and having a particle size, on average, less than 10 microns; optionally,
(vi) particles of glass forming 0 to 25% weight percent of the composition and having a diameter, on average, up to 20 microns and comprising soda-lime-silica glass having a melting point of at least about 1700°F; and (vii) zinc oxide forming 0 to 10 weight percent of the composition.
In addition, preferably the composition comprises small amounts of aluminum hydroxide. The invention, in another aspect, is a preferred process of making the above disclosed water-based paint which comprises (a) combining powders of the metal oxide colorants, low melting frit, any soda-lime-silica glass, and any zinc oxide, (b) heating the mixture to melt the powders together, cooling the melt and grinding the resultant material to form powder of desired particle size. These powders is then mixed with the silicate dissolved in water and the pH of the liquid mixture adjusted using the hydroxide to form the paint. According to still another aspect of the invention, it is a cured coating of the paint on a glass sheet .
Detailed Description of Preferred Embodiments
The invention composition is a water-based paint useful as a coating on glass, such as for the "black out" area around the periphery of a windshield. The glass paint components comprise, as disclosed in detail above, alkali metal silicate including hydrated silicate, water, water- soluble base, metal oxide powder like copper oxide, low- melting glass frit powder, and optionally, one or both of high-melting glass particles comprising soda-lime-silica glass and zinc oxide. The components of the composition will be discussed further below. The metal oxide powder, e.g., copper oxide, contributes to give the paint its black to gray color. As pointed out above, it may be desired to make the paint darker to match other paint on the glazings of the vehicle or merely for aesthetic appearance. I unexpectedly found, however, that to make the paint darker black-grey, the addition of more metal oxide powder was not advantageous. Rather, I found that by including hydrated silicate the glass was made blacker without the addition of more metal oxide powder. I believe that the reason for this darkening of the paint is that the hydrated silicates melt at a relatively low temperature, i.e., generally below 100°C, which give them the ability to wet the surface of the metal oxide colorant powder as it melts and which caused the metal oxide powder to appear darker. Neither the truth nor understanding of this theory is necessary for the practice of the invention. It is put forth in an effort to explain the unexpected darkening of the paint color without any additional metal oxide colorant being added.
Water-soluble silicates form between about 5 and 50 weight percent of the composition of this invention. Of those composition silicates up to 40 weight percent are sodium silicates and the balance is hydrated alkali metal silicates. More preferably, the paint composition comprises between about 0 and 10 weight percent sodium silicates, as "sodium silicates" is used herein it means not-hydrated alkali metal silicates, in contrast to alkali metal silicate hydrate. Most preferably about 5-10 weight percent sodium silicates are used. As used herein "weight percent of the composition" meaning a fraction of the total weight of the paint composition. These sodium silicates may comprise a single sodium silicate or a mixture of such silicates. Water-soluble sodium silicates useful in this invention composition can be represented by the formula Si02:Na20, wherein the mole ratio therein of the two oxides is from about 2:1 to about 4:1. In addition to the water-soluble sodium silicate, water- soluble potassium silicates of similar formula may also be included in the composition. When they are included, they are generally present in minor amounts, preferably less than 5 percent by weight, generally between about 5 and 10 weight percent of the composition.
Yet another required component of the composition is hydrated alkali metal silicates, which comprise all of part of the 5-50 weight percent of the composition silicates disclosed above. Preferably, these alkali metal silicate hydrates comprise about 10 to 30 weight percent of the paint composition. Hydrated alkali metal silicate can be any such material, the pentahydrate form being the most commonly available. In addition, however, the hexahydrate, octahydrate, and nonahydrate forms are well known and commonly available. All such materials have melting points below 100°C as is desired. Sodium forms such as sodium meta silicate pentahydrate are useful as well as the potassium forms of these hydrates. It is preferable to include in the paint composition, in addition to the alkali metal silicate hydrates, some non- hydrated forms of the silicates like sodium silicate because the non-hydrated sodium silicate forms cured paints with improved durability. If desired, however, all of the silicates of the paint composition may be alkali metal silicate hydrates.
Water, which is included in an amount between about 10 and 30 weight percent of the total paint composition, is preferably included in an amount between about 10 and 20 weight percent. In making the paint, optimally it is formulated in two parts which are then combined before application on the surface, of e.g., glass. One of the two parts is made by dissolving the silicates in the water.
The composition further comprises finely divided metal oxide pigment selected from copper oxide, iron oxide, nickel oxide, cobalt oxide and mixtures thereof, with the inclusion of copper oxide being preferred. This pigment gives the paint a black color and forms 20 to 40 weight percent of the composition, preferably between about 20 to 35 weight percent of the composition. The finely divided powder pigment has a particle size (diameter) on average less than about 7 microns, preferably being between about 3 and 7 microns, most preferably being about 5 microns. These compositions would vary in color from black to dark gray, depending on the mixture and percentages of the metal oxides. Copper oxide, which is preferred, provides a black paint composition. It is undesirable to use chromium oxide in the paint composition since it interferes with the adhesion of the paint to the glass.
The paint also includes a glass frit powder which is a low-melting glass material which melts below about 1300°F. Optimally it is included in the water based paint composition in an amount comprising 15-40 weight percent, more preferably being between about 20 and 40 weight percent, most preferably being between about 20 and 35 weight percent of the present invention blackish paint composition. The low-melting glass frit is used in a powder form, the particle diameter being on average less than about 10 microns, preferably being between about 3 and 7 microns, most preferably being on average about 7 microns. Exemplary of preferred glass frit materials useful in the present composition, -often referred to as enamel frits, are silicates of metals such as zinc, boron, bismuth, titanium, zirconium, and aluminum and mixtures thereof, e.g., titanium-silicate glass, zinc boro-silicate glass and bismuth boro-silicate glass. Many such glass frits are readily commercially available as from General Colors Co. and O. Hommell Co. Still other glass frits which may be employed in the present invention will be apparent to those skilled in the art in view of the present disclosure. The low-melting glass frit serves to improve paint adhesion to the glass, to PVB which may be used in a windshield laminate, and urethane which is often used to seal and attach the glass in an automotive vehicle. As is known, PVB is used within laminated windshields and urethane sealants are used between the glass and the car body.
In addition to the above required components, the paint composition optionally includes particles of soda-lime- silica glass which is a high-melting glass frit. This component contributes to improved temperature stability of the paint and adhesion to the glass on which it is applied. The particles are made of any soda-lime-silica glass, this type of glass being well known in the glass industry. Soda-lime-silica glass, used in the automotive and architectural industries, is commonly made by the float glass process. It is generally characterized by the following basic composition, the amounts of the components being based on a weight percentage of the total glass composition: silicon dioxide 68-75; aluminum oxide 0-5; calcium oxide 5-15; magnesium oxide 0-10; sodium oxide 10- 18; and potassium oxide 0-5. Additionally, the calcium oxide + magnesium oxide is 6-15%, and sodium oxide + potassium oxide is 10-20%. Such glasses can include colorants like iron oxide, cobalt oxide, or. copper oxide to name a few. Often UV absorbers like titanium oxide or cerium oxide are incorporated to improve the optical properties. Soda-lime-silica glasses, either with or without such colorants or other additives may be used in the present invention paint composition. Desirably, glass particles included in the paint composition would be similar or identical to the glass on which the paint will be applied, however, such is not necessary. The use of a particular soda-lime-silica glass is not critical to the present invention. The glass particles may be in powder or spherical form. Generally, the diameter of the particles is, on average, up to 20 microns, being preferably 3 to 15 microns. More preferably, the particles have a diameter in the range of about 5 to 7 microns .
The soda-lime-silica particles are optionally included in the paint composition in an amount up to 25 weight percent based on total weight of the paint composition.
Preferably, when included, the amount of such high-melting glass particles in the water-based paint is up to 20 wt . percent, optimally being up to 10. These particles may be obtained by grinding the glass to a desired diameter or obtained commercially. Spherical particles are most desirable when the paint is to be applied by screen printing, since they are less abrasive to the screen. Spherical particles are commercially available, for example, from Cataphote Inc., under the name Glas-Shottm. In the case of spherical particles the size may be 5 to 20 microns or even smaller since they optimally suitable for use, however smaller sizes are not as readily commercially available .
The chromium-free paint may further include an adhesion promoter: zinc oxide. This adhesion promoter, like the low-melting glass frit, promotes the adhesion of the paint to the glass. And, in addition, when the paint is used in contact with vinyl as in a laminated windshield, these adhesion promoters also promote the adhesion of the vinyl to the glass as described below.
When zinc oxide is included in the composition, it comprises generally about up to 10 weight percent, preferably being 2 to 10 weight percent, and more preferably between about 3 and 6 weight percent. Optimally, when included, it comprises between about 4 and 6 weight percent based on the weight of the composition. The zinc oxide is preferred to be provided in the paint composition in a particle size of between about 2 and 3 microns on average, however particle size is not critical.
The water-soluble base is employed to provide the paint composition with a pH of at least about 12, preferably being above 12.5, more preferably about 13.5 or above. The pH is required to be on the basic side as is indicated by the required pH . Providing the composition with this pH is necessary to impart desirable shelf life to the paint. Embodiments of invention paints with a pH above about 13, for example, have been found to be shelf stable for at least 3 months. Examples of water-soluble bases which may be employed include but are not limited to sodium hydroxide and potassium hydroxide, with sodium hydroxide being preferred. The amount of base employed is dependent, e.g., on the particular base and concentration employed. For example, using a 2N sodium hydroxide base, is generally included in about 2 to 10 weight percent of the composition, more preferably in about 3 to 8 weight percent, and most optimally, in about 3 to 6 weight percent. Optimal amounts and types of bases which may be employed would be apparent to those skilled in the art in view of the present disclosure.
In forming the paint composition, as mentioned above two parts are optimally formed and then mixed together. The first part is the silicates dissolved in the water. The second part is formed of the other solid materials discussed above: the metal oxide colorants, the low melting glass frit, and soda-lime-silica and/or zinc oxide when used. To form this second part, these solid materials would be mixed together and heated to melt them together. After the melt is cooled, it is ground to a powder of desired particle size, generally of less than 10 microns, preferably, 5 to 7 microns. Then the first part which is a liquid and the second part which is a powder are combined to form a liquid paint mixture and the pH of the liquid mixture adjusted with the water-soluble base.
Still another optional, but desirable, component included in the black paint composition of this invention is a surfactant. Surfactants are well known materials and often added to paints to improve the wetting characteristics of the liquid paint to the substrate to which it is applied. Exemplary of one such material is "FC-171" made by 3M Company. Still other surfactants are known to those skilled in the art. Desirably, it forms about 0.1 to 1.0 weight percent of the paint composition, more preferably about 0.25 to 0.5 weight percent. The surfactant would be generally added to the final paint composition.
Another optional but desirable component is aluminum hydroxide which is preferably included in the composition in up to about 5% by weight of the composition. It is generally added to the paint as aluminum hydroxide hydrate and has been found to increase the shelf life of the paint and may increase the adhesion of the paint to the glass sheet. In forming the paint composition, it would generally be added to the final paint composition.
While this paint composition has particular utility on soda-lime-silica glass as used in automotive and architectural glass, its use is not meant to be so limited. It may also find application for use on other glass like spandrel or on decorative glass panels or even other substrates, other than glass.
To make the paint composition, the components may be added together and then ball milled until a substantially uniform mixture of components is obtained. This milling may also be carried out to provide the desired particle size of the components, for example the glass particles and optional components like the glass frit, if they are initially present in particles sizes which are larger than desired in the final paint. A more preferred method for making the paint composition involves the two-part technique described above. By mixing the powders together and then melting them together, the final ground powder is a well mixed dispersion of all solids. This melting, cooling and subsequent grinding breaks up any agglomerates and provides a substantially uniform mixture of the solids. This solids mixture is then incorporated with the first part (dissolved silicates) with mixing to form the paint. The paint composition made this way was found to be easily painted onto glass surfaces by conventional techniques such as silk screenings. This mixing is generally carried out at room temperature. The base is preferably added after mixing of the two parts, but may also be added into the first part. Ideally, however, I prefer to add base just before the paint is to be used.
After making the subject invention composition, it may be applied to a substrate, particularly a glass substrate in the case of automotive "black-out", by any technique. The glass sheet may be prepared from any type of glass generally known in the art of glass making. Typical glass sheets contemplated for use according to the present invention are soda-lime-silica automotive and architectural glazings, generally produced by the well- known float glass process.
In the application disclosed above, the paint is applied as a uniform layer to a surface of the glass sheet in a predetermined pattern by any paint application method, e.g., screen printing wherein the paint is spread across the screen by a squeegee to force the paint through the pattern onto the glass sheet. It is well known in the painting arts to apply a band of paint to the surface of an automotive glazing by screen printing. In such a situation, it is particularly desirable to maintain a moist environment surrounding the paint during the screening process. Optimally the moist environment is maintained about 80+5% rh with the present invention preferred paint compositions. Maintaining this moist environment allows for prolonged use of the paint application screen system by maintaining the moisture content of the paint at a desirable viscosity for application. This environment may be optimally provided, e.g., by the invention described in U.S. Patent 5,509,964 to Boaz and commonly assigned with this invention. It is entitled "Apparatus and Method for Applying a Coating to Glass".
The predetermined pattern in which the paint may be applied to a glass sheet may comprise, for example, an opaque concealment band positioned on a peripheral marginal surface of an automotive glazing. Such concealment bands are well known in the art of automotive glazings as useful for preventing the solar radiation induced degradation of adhesives used to mount the glazings in a vehicle opening, and for concealing attachment hardware and structural components which lie below the edges of the glazings. The band generally extends to the edges of the glazings, and has a width sufficient to conceal the underlying adhesive and structural components, but which is sufficiently narrow to provide maximum vision to occupants of the vehicle. Clearly, other predetermined patterns may be utilized where applying various paint fields to glass surfaces, depending upon the ultimate purpose for the cured paint field.
In the case of coatings applied to automotive glass as "black out", the coating is preferably provided in a thickness of about 12-16 microns. The coating may be applied in any thickness, however, the optimal thickness being determined by the particular application desired.
The curable compositions of the invention, after being applied to a substrate, are readily cured by baking at an elevated temperature for a time sufficient to drive off the water which cures the coating. This step may be carried at any temperature, but desirably at a temperature below the softening point of the glass. Since this water vaporization and curing can be preferably carried out at moderate temperatures, e.g., below about 400°C, even between about 100°C and 200°C, the painted glass is not subjected to softening and hence is prevented from being distorted during the moderate temperature.
This is in contrast to conventional organic vehicle paints which require being heated to temperatures above the softening point of the glass to cure these paints. Paint compositions applied to glass sheets are generally first cured in order to make the painted glass available for handling for further processing, i.e., bending of the painted glass sheet into a desired final shape. Heating glass to temperatures above the softening point of the glass to cure organic vehicle paints provides the glass with an opportunity to pick up distortions. Subsequent bending of the painted glass, in a second firing, again at these high temperatures provides a second opportunity for distortions to be incorporated into the glass product. Hence, the present invention paint, because it can cure at relatively low temperatures below the softening point of the glass, desirably minimizes the opportunity for distortion to be incorporated into the glass product.
This drying and curing of the water-based black paint composition may be carried out by any means. Two particularly preferred means comprise subjecting the paint applied to the glass to Infra Red (IR) radiation or microwave radiation as in a microwave oven. The latter is most particularly preferred because it may be provided as a compact unit of relatively small size, it consumes less energy and generally requires less maintenance.
In the case of a windshield type 12" x 12" sample which had an embodiment of the invention paint composition applied to a portion of its surface as a "black out" band, it was found that the coating could be cured in about one minute at 150 °C in an IR oven or less than about 1 minute in a microwave oven (4 KW power) . The particular embodiment of paint composition employed and the area coated suggest the optimal particular parameters useful to cure the invention paint.
As is evident, the present invention moderate temperature curable compositions are of considerable advantage in that they provide for significant energy savings in comparison to compositions which require significantly elevated temperatures for curing. In addition, as discussed above, when the substrate is glass, optical distortions can be incorporated into the glass sheet when it is exposed to significantly elevated temperatures as required to cure conventional organic vehicle glass coatings. The present invention composition overcomes this disadvantage of prior art coatings which require elevated temperatures for curing the paint. While, as described above, the paint finds particular usefulness on glass, it may also be used to paint other substrates, including, e.g., metal or plastic .
Generally, coated automotive glass will subsequently be subjected to shaping which involves subjecting the glass to high temperatures of the order of 1150°F or more, which can be 1250°F or more if the glass is tempered. This will allow the coating to further cure, although such is not required to provide a durable and adherent coating on a substrate.
The following examples are presented by way of description of the invention and to set forth the best mode contemplated by the inventor, but are not to be construed as limiting.
Examples
The following three examples are embodiments of paint compositions made according to the present invention. All component amounts are in weight percent of the total paint composition . Paint #
Sodium meta-silicate 15 10 30 (penta-hydrate )
Sodium silicate 5
Ground glass 0 (Soda-lime-silica 7μ diameter)
Potassium silicate 0
Water 10 20 20
Sodium hydroxide (50% solution)
Copper oxide 33.9 26.9 24.9
Zinc oxide 1.0
Glass frit 33.8 30.8 20.8
(bismuth borosilicate)
Surfactant 0.3 0.3 0.3
(FC-171, 3M Company)
The black paint compositions above, embodiments of the present invention, were made in two parts as described above. In forming the second part, the powders were heated and calcined at 975 degrees F for 6 hrs. and then cooled and ground into a powder mixture having a particle size of about 7 microns. The two parts were then combined and mixed for 6 minutes, and the mixture adjusted with the hydroxide and then surfactant was added. The paint had a pH of about 13.5.
The paint was applied by screen printing to glass (soda- lime-silica) sheets to a thickness of 16 microns and cured in an oven which heats the glass to over 550°C and fully cures the paint. The paint had a dark black color and developed rapidly during the heating process.
Four other paint compositions were made as follows, #4 and #5 being embodiments of the present invention, while #6 and #7 are comparative examples, not according to the present invention.
Paint No.
#4 #5 #6 #7
Sodium Meta-silicate 15 20 0 0
Sodium Silicate 6 6 15 16
Soda-Lime-Silica Glass 0 0 0 0
Potassium Silicate 2 2 1.8 1.8
Water 10 10 20 20
Copper Oxide 32.4 29.9 31 28
Glass Frit 32.4 29.9 25 30
(bismuth borosilicate)
Zinc Oxide 0 0 3.0 2.0
Aluminum Hydroxide 0 0.0 2.0 0
Sodium Hydroxide 2.0 2.0 2.0 2.0
(50%)
Surfactant 0.2 0.2 0.2 0.2
(FC-171, 3M Company) The compositions were made following the two part process of Example 1 and applied to glass panels and cured at 550°C. These paints were evaluated visually for speed of color development. Paints #4 and #5 obtained a dark black color in 1 minute while paints #6 and #7 obtained an unacceptable flat gray-black color in the same time period and temperature. The fact that the invention paint samples cured and developed the dark black color rapidly desirably allows for high production speeds. The use of this invention paint was also found to lessen the criticality of controlling the curing temperature during production. That is, even in operations with older manufacturing equipment where cure temperatures may fluctuate, acceptable coatings are still achieved.
All of the invention embodiment paints displayed excellent durability when tested.

Claims

Claims
1. A dark colored water-based paint composition with excellent durability on glass, comprising: (i) water-soluble alkali metal silicate forming
5 to 50 weight percent of said composition including up to 40 weight percent sodium silicates and the balance being hydrated alkali metal silicates; (ii) water forming 10 to 30 weight percent of said composition; (iii) water-soluble base in an amount sufficient to provide said composition with a pH of at least 12; (iv) finely divided metal oxide powder selected from the group consisting of oxides of copper, iron, nickel, cobalt and mixtures thereof forming 20 to 40 weight percent of said composition and having a particle size, on average, less than 7 microns;
(v) low-melting glass frit powder melting below 1300°F forming 15 to 40 weight percent of said composition and having a particle size, on average, less than 10 microns; (vi) particles of soda-lime-silica glass forming
0 to 25 weight percent of the composition and having a diameter, on average, less than 20 microns and having a melting point of at least about 1700°F; and (vii) zinc oxide forming 0 to 10 weight percent of said composition.
2. The water-based paint composition according to claim 1 wherein said soda-lime-silica particles are composed of, by weight percent, silicon dioxide 68-75; aluminum oxide 0-5; calcium oxide 5-15; magnesium oxide 0-10; sodium oxide 10-18; and potassium oxide 0-5, wherein the calcium oxide + magnesium oxide is 6-15% and sodium oxide + potassium oxide is 10-20% by weight.
3. The water-based paint composition according to claim 1 wherein said alkali metal silicate hydrate is selected from the group consisting of hydrated sodium or potassium silicate .
4. The water-based paint composition according to claim 1 wherein said low-melting glass frit powder forms 20 to 40 weight percent of said composition.
5. The water-based paint composition according to claim 1 wherein said composition further comprises 0.1 to 1.0 weight percent surfactant.
6. The water-based paint composition according to claim 1 which further comprises up to about 5 weight percent of aluminum hydroxide.
7. The water-based paint composition according to claim 1 wherein said low-melting glass frit is selected from a metal silicate wherein said metal is selected from the group consisting of zinc, boron, bismuth, titanium zirconium, and aluminum and mixtures thereof.
8. The water-based paint composition according to claim 1 wherein the hydrate comprises 10-30 weight percent of the composition.
9. A method of making a water based paint composition whose components comprise:
(i) water-soluble alkali metal silicate forming
5 to 50 weight percent of said composition including up to 40 weight percent sodium silicates and the balance being hydrated alkali metal silicates;
(ii) water forming 10 to 30 weight percent of said composition; (iii) water-soluble base in an amount sufficient to provide said composition with a pH of at least 12;
(iv) finely divided metal oxide powder selected from the group consisting of oxides of copper, iron, nickel, cobalt and mixtures thereof forming 20 to 40 weight percent of said composition and having a particle size, on average, less than 7 microns;
(v) low-melting glass frit powder melting below 1300°F forming 15 to 40 weight percent of said composition and having a particle size, on average, less than 10 microns;
(vi) particles of soda-lime-silica glass forming
0 to 25 weight percent of the composition and having a diameter, on average, less than 20 microns and having a melting point of at least about 1700°F; and
(vii) zinc oxide forming 0 to 10 weight percent of said composition, said method comprising the steps: forming a first part by mixing the silicates and water, forming a second part by mixing and melting powders (iv)-(vii) together to form a melted mixture, cooling the melted mixture and forming therefrom a powder having a particle diameter of, on average, less than 10 microns; combining the first part and the second part and adjusting the pH with the water-soluble base to form the paint composition.
10. A glazing carrying on at least a portion thereof a paint composition according to claim 1.
PCT/GB2000/004377 1999-12-10 2000-11-20 Water-based ceramic paint darkened with silicate hydrates WO2001042374A1 (en)

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US7547651B2 (en) * 2006-08-11 2009-06-16 Applied Technology Laboratories Llc Metal cladding composition
WO2014164240A1 (en) * 2013-03-12 2014-10-09 Guardian Industries Corp. Method of making a coated article and/ or glazing for automobiles and/or the like
US9567258B2 (en) 2013-03-12 2017-02-14 Guardian Industries Corp. Picture frame with glass mat, and/or method of making the same
US10882780B2 (en) 2015-10-23 2021-01-05 Pilkington Group Limited Process for manufacturing a glazing, and glazing thereby produced

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7547651B2 (en) * 2006-08-11 2009-06-16 Applied Technology Laboratories Llc Metal cladding composition
WO2014164240A1 (en) * 2013-03-12 2014-10-09 Guardian Industries Corp. Method of making a coated article and/ or glazing for automobiles and/or the like
US8993104B2 (en) 2013-03-12 2015-03-31 Guardian Industries Corp. Method of making a coated article and/or glazing for automobiles and/or the like
US9567258B2 (en) 2013-03-12 2017-02-14 Guardian Industries Corp. Picture frame with glass mat, and/or method of making the same
US10882780B2 (en) 2015-10-23 2021-01-05 Pilkington Group Limited Process for manufacturing a glazing, and glazing thereby produced

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