GB1372237A - Process for the production of an article having an integral mirror surface - Google Patents

Abstract

1372237 Laminates; injection moulding PICTORIAL PRODUCTIONS Inc 8 Sept 1971 [25 Sept 1970 21 May 1971] 41891/71 Headings B5N and B5A [Also in Division G2] An injection moulded thermoplastic article having an integral mirror surface is produced by placing in a mould cavity a flexible reflective foil comprising (a) a substrate layer adapted to combine and remain together with the moulded article without undesirable separation therefrom, (b) a smooth and clear protective layer bonded to the substrate layer and (c) a metallized layer disposed between the substrate and protective layers, with the substrate layer facing the interior of the mould cavity, injecting a thermoplastic resin into the mould cavity, allowing the resin in the mould cavity to cool and removing the article from the mould, the protective layer being so smoothed during injection moulding of the article that the pro-- tective layer and metallized layer co-operate to specularly reflect visible light thereby providing a mirror surface. The substrate layer may be a plastic film or coating, scrim, paper or floe, e.g., a film of a polyamide, polyethylene, polypropylene, ABS, styrene-acrylonitrile, polystyrene optionally containing rubber, polycarbonate, vinyl or methyl methacrylate polymer. The protective layer which preferably has a high degree of light transmission and a high degree of surface gloss on both surfaces, may be a.film or coating of polyethylene terephthalate, acrylic, styrene-acrylonitrile, polyvinyl chloride, polyethylene, polypropylene, polystyrene, cellulose acetate, polycarbonate, polysulphone or cellulose acetate butyrate. The reflective metallized layer may be a foil of tin, aluminium or gold or may be deposited on the substrate layer or protective layer by vacuum metallization. Lamination of the protective layer to the reflective metallized layer and/or of the reflective metallized layer to the substrate layer may be effected using heat activated adhesives, hot or cold pressure laminating, ultrasonic walding, heat planishing or extrusion laminating techniques. The reflective foil may be subjected to hot stamping decoration prior to moulding or embossed moulds may be used. Magnifying or reducing mirrors having convex or concave surfaces may be produced.