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TOMMUNO DUE
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`
`USO10052850B2
`
`( 12 ) United States Patent
`Weiss et al .
`
`( 10 ) Patent No . : US 10 , 052 , 850 B2
`( 45 ) Date of Patent :
`Aug . 21 , 2018
`
`( 54 ) ENCAPSULATED PLASTIC PANEL AND
`METHOD OF MAKING THE SAME
`( 71 ) Applicant : EXATEC , LLC , Wixom , MI ( US )
`( 72 ) Inventors : Keith D . Weiss , Fenton , MI ( US ) ;
`Steven M . Gasworth , Wixom , MI
`( US ) ; Sunitha K . Grandhee , Novi , MI
`( US ) ; Wilfried Hedderich , Hilden ( DE )
`( 73 ) Assignee : EXATEC , LLC , Wixom , MI ( US )
`Subject to any disclaimer , the term of this
`( * ) Notice :
`patent is extended or adjusted under 35
`U . S . C . 154 ( b ) by 89 days .
`( 21 ) Appl . No . : 14 / 842 , 164
`Sep . 1 , 2015
`( 22 )
`Filed :
`Prior Publication Data
`( 65 )
`US 2015 / 0367612 A1 Dec . 24 , 2015
`
`( 60 )
`
`( 51 )
`
`( 52 )
`
`( 58 )
`
`Related U . S . Application Data
`Continuation of application No . 14 / 467 , 133 , filed on
`Aug . 25 , 2014 , now Pat . No . 9 , 139 , 242 , which is a
`( Continued )
`
`Int . Ci .
`B32B 3 / 10
`B32B 27 / 08
`
`U . S . CI .
`
`( 2006 . 01 )
`( 2006 . 01 )
`( Continued )
`B32B 27 / 08 ( 2013 . 01 ) ; B29C 45 / 14336
`( 2013 . 01 ) ; B29C 45 / 14811 ( 2013 . 01 ) ;
`( Continued )
`Field of Classification Search
`None
`See application file for complete search history .
`
`( 56 )
`
`EP
`EP
`
`References Cited
`U . S . PATENT DOCUMENTS
`4 , 076 , 788 A
`2 / 1978 Ditto
`4 , 081 , 578 A
`3 / 1978 Van Essen et al .
`( Continued )
`FOREIGN PATENT DOCUMENTS
`0285870 A2 10 / 1988
`0597624 A15 / 1994
`( Continued )
`OTHER PUBLICATIONS
`Material Safety Data Sheet Thermocure 948 ( http : / / diverprint . com /
`images / stories / msds / P - Line - Inks - and - Solvents /
`MSDS _ Proell _ Thermo - Jet / Thermo - Jet - 948 _ MSDS . pdf ) retreived
`on Jan . 23 , 2017 . *
`( Continued )
`Primary Examiner — Christopher Polley
`( 74 ) Attorney , Agent , or Firm — Cantor Colburn LLP
`( 57 )
`ABSTRACT
`An economical method of manufacturing a plastic glazing
`panel having an encapsulation for aesthetic purposes and to
`enhance the sealing of the glazing panel to the vehicle is
`presented . This method includes the steps of forming a
`plastic panel having an A - side and B - side ; printing an
`opaque border from an ink with the border being in contact
`with the B - side of the panel and substantially encircling the
`perimeter of the panel ; curing the ink of the opaque border ;
`applying a weatherable layer on the printed border and the
`plastic panel ; curing the weatherable layer ; depositing an
`abrasion resistant layer on the weatherable layer ; placing the
`plastic panel into a mold having a soft gasket ; injecting an
`elastomeric material to form an encapsulation that substan
`tially encircles the perimeter of the plastic panel and encom
`passes the A - side ; B - side and edge of the plastic panel ; and
`removing the plastic panel from the mold .
`19 Claims , 3 Drawing Sheets
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`APPLE 1031
`
`

`

`US 10 , 052 , 850 B2
`Page 2
`
`( 51 )
`
`( 52 )
`
`( 2006 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`( 2014 . 01 )
`( 2014 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`
`Related U . S . Application Data
`division of application No . 12 / 113 , 656 , filed on May
`1 , 2008 , now abandoned .
`( 60 ) Provisional application No . 60 / 915 , 274 , filed on May
`1 , 2007 .
`Int . CI .
`B29C 45 / 14
`B29C 70 / 76
`B60J 1 / 00
`B60J 7 / 00
`C09D 11 / 101
`C09D 11 / 104
`B32B 38 / 00
`B62D 65 / 06
`B32B 27130
`B32B 2736
`B29L 31 / 30
`B29L 31 / 00
`U . S . CI .
`CPC . . . . . . . . . . B29C 70 / 763 ( 2013 . 01 ) ; B32B 27304
`( 2013 . 01 ) ; B32B 27 / 365 ( 2013 . 01 ) ; B32B
`38 / 00 ( 2013 . 01 ) ; B32B 38 / 145 ( 2013 . 01 ) ;
`B60J 1 / 00 ( 2013 . 01 ) ; B60J 7700 ( 2013 . 01 ) ;
`B62D 65 / 06 ( 2013 . 01 ) ; C09D 11 / 101
`( 2013 . 01 ) ; C09D 11 / 104 ( 2013 . 01 ) ; B29C
`45 / 14434 ( 2013 . 01 ) ; B29C 2795 / 00 ( 2013 . 01 ) ;
`B29K 2995 / 002 ( 2013 . 01 ) ; B29K 2995 / 0025
`( 2013 . 01 ) ; B29K 2995 / 0087 ( 2013 . 01 ) ; B29L
`2031 / 30 ( 2013 . 01 ) ; B29L 2031 / 778 ( 2013 . 01 ) ;
`B32B 2255 / 10 ( 2013 . 01 ) ; B32B 2255 / 20
`( 2013 . 01 ) ; B32B 2255 / 26 ( 2013 . 01 ) ; B32B
`2255 / 28 ( 2013 . 01 ) ; B32B 2305 / 72 ( 2013 . 01 ) ;
`B32B 2307 / 41 ( 2013 . 01 ) ; B32B 2307 / 584
`( 2013 . 01 ) ; B32B 2307 / 712 ( 2013 . 01 ) ; B32B
`2605 / 006 ( 2013 . 01 ) ; Y10T 428 / 239 ( 2015 . 01 ) ;
`YIOT 428 / 24777 ( 2015 . 01 )
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`10 / 2008 Leclercq et al .
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`10 / 2011 Wootton
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`
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`428 / 411 . 1
`
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`EP
`JP
`WO
`wo
`WO
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`et
`al : “ Automobilscheiben aus Kunststoff , "
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`International Search Report and Written Opinion of the Interna
`tional Searching Authority ; International Application No . PCT /
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`
`2
`
`

`

`US 10 , 052 , 850 B2
`Page 3
`
`( 56 )
`
`References Cited
`OTHER PUBLICATIONS
`Written Opinion of the International Searching Authority ; Interna
`tional Application No . PCT / US2008 / 061748 ; International Filing
`Date : Apr . 28 , 2008 ; dated Sep . 11 , 2008 ; 15 pages .
`* cited by examiner
`
`3
`
`

`

`U . S . Patent
`
`Aug . 21 , 2018
`
`Sheet 1 of 3
`
`US 10 , 052 , 850 B2
`
`25
`
`10
`
`OG
`
`Figure 1
`
`4
`
`

`

`U . S . Patent
`
`Aug . 21 , 2018
`
`Sheet 2 of 3
`
`US 10 , 052 , 850 B2
`
`
`
`Applying the Weatherable Layer
`
`Curing the Printed Ink
`
`35
`
`
`the Opaque Pattern
`Printing
`
`hether
`
`W
`
`A - side
`
`B - side
`
`
`
`Forming the Plastic Panel
`
`30
`
`50
`
`
`the Weatherable Layer
`Curing
`
`Depositing the Abrasion Resistant
`Layer
`
`60
`
`Placing the
`Panel into a Mold
`the Encapsulation
`E - = - - =
`Forming
`65
`Removing the Panel
`
`
`from the Mold
`
`Figure 2
`
`5
`
`

`

`U . S . Patent
`
`Aug . 21 , 2018
`
`Sheet 3 of 3
`
`US 10 , 052 , 850 B2
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`

`

`US 10 , 052 , 850 B2
`
`5
`
`ENCAPSULATED PLASTIC PANEL AND
`METHOD OF MAKING THE SAME
`
`Second , plastic glazing systems are not as hard as a
`conventional glass window . Thus the trimming of any
`“ flash ” material created by the encapsulation process will
`result in irreversible damage to the coating system of the
`CROSS REFERENCE TO RELATED
`plastic glazing panel . This damage will ultimately result in
`APPLICATIONS
`premature degradation of the properties exhibited by the
`plastic glazing panel .
`This application is a continuation of U . S . Nonprovisional
`Finally , plastic glazing panels exhibit different thermal
`application Ser . No . 14 / 467 , 133 filed on Aug . 25 , 2014
`expansion characteristics than glass windows . Thus heating
`which is a divisional application of U . S . Nonprovisional
`application Ser . No . 12 / 113 , 656 filed on May 1 , 2008 which 10 the surface of the plastic glazing panel to activate any
`claims the benefit of U . S . Provisional Application Ser . No .
`adhesion promoter used to facilitate adhesion between the
`60 / 915 , 274 filed on May 1 , 2007 , the entire contents of
`plastic glazing panel and the encapsulation will cause sub
`stantial distortion to the shape of the window . Such a
`which are incorporated herein by reference .
`distortion will result in the operator having difficulty in
`TECHNICAL FIELD
`15 securing the window into the mold during the encapsulation
`process . Thus this process will suffer from an increase in
`This invention relates to plastic glazing panels that are
`cycle time and an overall loss in productivity .
`encapsulated to promote sealing and appearance when used
`Therefore , there is a need in the industry to develop a
`plastic glazing panel and a process in which the plastic
`as a window or sunroof .
`20 glazing panel can be encapsulated without degrading the
`BACKGROUND
`properties exhibited by the plastic glazing panel or affecting
`cycle time or productivity .
`For a number of years , car manufacturers have favored
`BRIEF SUMMARY
`window encapsulation for the sealing of automotive glass .
`Such encapsulation technology includes molding an elasto - 25
`meric gasket directly onto the surface of the glass . These
`An economical method of manufacturing a plastic glazing
`gaskets are typically made from a variety of materials
`panel having an encapsulation for aesthetic purposes and to
`including thermoplastic elastomers ( TPE ) and polyvinyl
`enhance the sealing of the glazing panel to the vehicle is
`chloride ( PVC ) , as well as cross - linked polyurethanes
`presented . This economical method includes the steps of
`applied via reaction injection molding ( RIM ) . The encapsu - 30 forming a plastic panel having an A - side and B - side ; print
`lation process for a conventional glass window may be
`ing an opaque border from an ink with the border being in
`described as including the steps of applying a primer or
`contact with the B - side of the panel and substantially
`adhesion promoter to the perimeter of the one side of the
`encircling the perimeter of the panel ; curing the ink of the
`window ; applying heat to this side of the window to activate
`opaque border ; applying a weatherable layer on the printed
`the primer ; placing the window in
`a mold ; injecting the 35 border and the plastic panel ; curing the weatherable layer ;
`thermoplastic elastomer onto the primer and the adjacent
`depositing an abrasion resistant layer on the weatherable
`surface of the window ; removing the window from the mold ,
`layer ; placing the plastic panel into a mold having a soft
`and trimming any excess elastomeric material that has
`gasket ; injecting an elastomeric material to form an encap
`accumulated at the interface between the window and the
`sulation that substantially encircles the perimeter of the
`encapsulation . Such excess or scrap elastomeric material is 40 plastic panel and encompasses the A - side , B - side , and edge
`known by one skilled - in - the - art of encapsulation as " flash ”
`of the plastic panel ; and finally removing the plastic panel
`material . The trimming of the " flash ” material is typically
`from the mold . The use of a soft gasket in the mold reduces
`done with a sharp object , such as a knife or razor blade . The
`or eliminates the occurrence of “ flash ” material being gen
`encapsulated glass window is then fixed into the opening of
`erated at the edge of the interface between the encapsulation
`a vehicle typically through the use of an adhesive system , 45 and the plastic glazing panel .
`such as the urethane BETASEALTM system offered by Dow
`Optionally the step of applying an adhesion promoter on
`Automotive , Auburn Hills , Mich .
`top of the abrasion resistant layer encircling the B - side
`The use of plastic glazing panels provides several issues
`perimeter of the plastic panel may take place prior to placing
`for the use of conventional encapsulation technology . First ,
`the plastic panel into the mold to form the encapsulation .
`plastic glazing panels are typically coated with a weather - 50 The plastic panel is then heated on the A - side and B - side of
`able coating system , such as the acrylic primer ( e . g . ,
`the plastic panel in close temporal proximity to activate the
`SHP401 and SHP470 ) and silicone hard - coat ( e . g . , AS4000
`adhesion promoter without substantially distorting the shape
`and AS4700 ) systems offered by Momentive Performance
`of the window .
`Materials , Wilton , Conn . in order for the glazing panel to
`In another embodiment of the present invention , the steps
`survive exposure to the environment . Unfortunately the 55 of printing an opaque border from an ink and curing the ink
`surface properties associated with a silicone hard - coat is
`on the plastic panel is replaced with the steps of printing an
`such that most conventional encapsulation materials cannot
`opaque border from an ink on to a plastic film ; curing the ink
`effectively adhere , thereby , creating a weakened interface
`on the plastic film ; and forming and adhering the opaque
`that will cause the plastic glazing after being fixed to a
`border and the plastic film to the B - side of the plastic panel
`vehicle to prematurely fail . The known remedy for this 60 so that the opaque border substantially encircles the perim
`situation has been to apply the encapsulation to the bare
`eter of the plastic panel .
`plastic panel ( e . g . , no protective coatings ) . However , this
`In another embodiment of the present invention , the
`solution requires a masking step before applying the weath
`encapsulated plastic glazing panel comprises a substantially
`erable coating and a de - masking step after the weatherable
`transparent plastic panel having an A - side , B - side , and an
`coating is cured . The addition of these two steps increases 65 edge ; an opaque border in contact with the B - side of the
`the costs associated with manufacturing an encapsulated
`plastic panel and that substantially encircles the perimeter of
`plastic glazing panel .
`the plastic panel ; a weatherable layer in contact with the
`
`7
`
`

`

`US 10 , 052 , 850 B2
`
`10
`
`then printing 35 an opaque border with an ink on the plastic
`opaque border and the plastic panel ; an abrasion resistant
`panel ; followed by curing 40 the printed ink ; applying 45 a
`layer in contact with the weatherable layer ; and an encap -
`weatherable layer onto the printed plastic panel ; curing 50
`sulation in contact with the abrasion resistant layer and that
`the weatherable layer , depositing 55 an abrasion resistant
`substantially encircles the perimeter of the plastic panel and
`encompasses the A - side . B - side , and edge of the plastic 5 layer onto the weatherable layer , placing 60 the panel into a
`mold ; forming 65 the encapsulation by injecting an encap
`panel .
`In another embodiment of the present invention , the
`sulating material to the outer perimeter of the glazing panel ,
`plastic glazing panel further comprises a plastic film that has
`and then removing 70 the encapsulated glazing panel from
`one side of the film in contact with the opaque border and the
`the mold .
`B - side of the plastic panel and the other side of the film in
`The transparent plastic panel may be formed 30 into a
`window , e . g . , vehicle window , from plastic pellets or sheets
`contact with the weatherable layer .
`In another embodiment of the present invention , the
`through the use of any known technique to those skilled - in
`weatherable layer may include a single layer or multiple
`the - art , such as extrusion , molding , which includes injection
`layers , such as a primer and a topcoat . The weatherable layer
`molding , blow molding , and compression molding , or ther
`uses ultraviolet absorbing ( UVA ) molecules to protect the 15 moforming , which includes thermal forming , vacuum form
`ing , and cold forming . It is to be noted that the forming 30
`plastic panel from UV radiation .
`In another embodiment of the present invention , the
`of a window using a plastic sheet may occur prior to printing
`abrasion resistant layer is deposited using a vacuum depo -
`as shown in FIG . 2 , after printing 35 and curing 40 of the
`sition technique . One example of an abrasion resistant layer
`ink , or after application 45 and curing 50 of the weatherable
`includes , but is not limited to , silicon oxy - carbide having a 20 coating without falling beyond the scope or spirit of the
`present invention . The use of plastic pellets to form 30 the
`composition ranging from SiO , to SiO , C , H , .
`Further areas of applicability will become apparent from
`plastic panel is done prior to printing 35 the opaque pattern .
`the description provided herein . It should be understood that
`An opaque border may be defined as a substantially
`the description and specific examples are intended for pur -
`opaque ink printed or applied 35 for decorative purposes
`poses of illustration only and are not intended to limit the 25 and / or to hide or mask other vehicle components ( e . g . ,
`adhesives ) . This opaque border may be applied 35 to the
`scope of the present disclosure .
`periphery of the transparent substrate to form a solid mask
`BRIEF DESCRIPTION OF THE DRAWINGS
`ing border . The opaque border may further include a fade
`out pattern to transition the border into the viewing region of
`The drawings described herein are for illustration pur - 30 the window . The fade - out pattern may incorporate a variety
`poses only and are not intended to limit the scope of the
`of shapes of variable size including dots , rectangles ( lines ) ,
`squares , and triangles , among others .
`present disclosure in any way .
`In one embodiment of the present invention , the opaque
`FIG . 1 is a depiction of an automobile window according
`border can be printed 35 onto the surface of the plastic panel
`to the principles of the present invention .
`FIG . 2 is a schematic of a manufacturing process for a 35 via screen printing . Other known methods of printing 35 the
`plastic glazing panel according to one embodiment of the
`opaque border on the plastic panel may also be utilized when
`deemed appropriate . A non - inclusive list of other known
`present invention .
`FIG . 3 is a diagrammatic representation of a cross - section
`printing methods include pad printing , membrane image
`of a glazing panel from FIG . 1 according to one embodiment
`transfer printing , cylindrical printing , digital printing ,
`40 robotic dispensing , mask / spray , ink - jet printing , and the like .
`of the present invention .
`The thickness of the printed ink may range from about 2
`DETAILED DESCRIPTION
`micrometers to about 1 mil ( 25 . 4 micrometers ) with about 6
`to 12 micrometers being preferred .
`The following description is merely exemplary in nature
`Once the ink is printed 35 , drying or curing 40 should be
`and is in no way intended to limit the present disclosure or 45 thorough in order to ensure that any retained solvent is
`its application or uses . It should be understood that through -
`removed from the print . The inks may be thermally cured by
`out the description and drawings , corresponding reference
`being exposed to an elevated temperature for a period of
`numerals indicate like or corresponding parts and features .
`time , cured upon exposure to UV radiation , or via a com
`The present invention provides a plastic glazing panel and
`bination thereof . The thickness of the cured ink print is
`an economical method of manufacturing such as a glazing 50 typically about 4 micrometers to 20 micrometers with
`panel that includes the application of encapsulation that
`between about 6 micrometers to 18 micrometers being
`substantially encircles the perimeter of the window . The
`preferred .
`plastic glazing panel also includes a decorative printed
`The weatherable layer is applied 45 to the printed panel by
`border and a protective coating system to provide a high
`dip coating , flow coating , spray coating , curtain coating ,
`level of weatherability and abrasion resistance . Referring to
`55 spin coating , or any other techniques known to those skilled
`FIG . 1 , a plastic glazing panel may be used as an automotive
`in - the - art . The thickness of the weatherable layer may range
`fixed side window 10 . The window 10 is shown having a
`from about 2 micrometers to several mils ( 1 mil = 25 . 4
`substantially transparent viewing area 15 , a printed opaque
`micrometers ) , with about 6 micrometers to
`1 mil being
`border 20 encompassing the transparent viewing area 15 ,
`preferred . The weatherable layer may then be cured 50 using
`and an encapsulation 25 encircling the perimeter of the 60 a mechanism selected as one of air drying , UV absorption ,
`glazing panel 10 . One skilled - in - the - art of automotive
`thermal absorption , condensation addition , thermally driven
`design will realize that the plastic glazing panel of the
`entanglement , cross - linking induced by cationic or anionic
`present invention can be used for other automotive win
`species , or a combination thereof .
`dows , such as a backlite , sunroof , and movable side win -
`The weatherable layer is over - coated via the deposition 55
`dows , among others .
`65 of an abrasion resistant layer . This abrasion resistant layer
`Referring to FIG . 2 , an economical manufacturing process
`may be either comprised of one layer or a combination of
`may generally be defined by first forming 30 a plastic panel ;
`multiple inter - layers of variable composition . The abrasion
`
`8
`
`

`

`US 10 , 052 , 850 B2
`
`substantially simultaneous application is found to minimize
`resistant layer is applied by any vacuum deposition tech
`or eliminate the occurrence of this distortion . The applica
`nique known to those skilled - in - the - art , including but not
`tion of heat to both sides of the window may be accom
`limited to plasma - enhanced chemical vapor deposition
`plished through the use of any means known to one skilled
`( PECVD ) , expanding thermal plasma PECVD , plasma
`in - the - art , including , but not limited to , IR heating or forced
`polymerization , photochemical vapor deposition , ion beam 5
`air heating
`deposition , ion plating deposition , cathodic arc deposition ,
`sputtering , evaporation , hollow - cathode activated deposi
`Referring now to FIG . 3 , a cross - section of a plastic
`tion , magnetron activated deposition , activated reactive
`glazing panel according to one embodiment of the present
`evaporation , thermal chemical vapor deposition , and any
`invention is shown . The plastic panel 15 may be comprised
`known sol - gel coating process .
`10 of any thermoplastic or thermoset polymeric resin . The
`In one embodiment of the present invention , a specific
`polymeric resins include , but are not limited to , polycarbon
`type of PECVD process used to deposit the abrasion resis
`ate , acrylic , polyarylate , polyester , and polysulfone , as well
`tant layers comprising an expanding thermal plasma reactor
`as copolymers and mixtures thereof . In order to function
`is preferred . This specific process ( called hereafter as an
`expanding thermal plasma PECVD process ) is described in 15 appropriately as a window and to allow for the dual curing
`of the printed ink , the plastic panel 15
`is substantially
`detail in U . S . patent application Ser . No . 10 / 881 , 949 ( filed
`Jun . 28 , 2004 ) and U . S . patent application Ser . No . 11 / 075 ,
`transparent .
`The printed ink 20 may be comprised of a thermally
`343 ( filed Mar . 8 , 2005 ) , the entirety of both being hereby
`incorporated by reference . In an expanding thermal plasma
`curable ink or a UV curable ink . A thermally curable ink may
`PECVD process , a plasma is generated via applying a 20 include a polyester - based binder , a polycarbonate - based
`direct - current ( DC ) voltage to a cathode that arcs to
`a
`binder , or a mixture thereof . A UV curable ink may include
`corresponding anode plate in an inert gas environment . The
`a mixture of various multifunctional acrylate oligomers and
`pressure near the cathode is typically higher than about 150
`monomers along with a photoinitiator . Examples of inks
`Torr , e . g . , close to atmospheric pressure , while the pressure
`include Exatec® PIX ( Exatec LLC , Wixom , Mich . ) and
`near the anode resembles the process pressure established in 25 DXT - 1599 ( Coates Screen , St . Charles , Ill . ) , among others .
`the plasma treatment chamber of about 20 mTorr to about
`The ink 20 may further comprise other additives , such as
`100 m Torr . The near atmospheric thermal plasma then
`colorants ( e . g . , pigments and / or dyes ) , fillers , surfactants ,
`supersonically expands into the plasma treatment chamber .
`defoamers , tackifiers , adhesion promoters , viscosity promot
`The reactive reagent for the expanding thermal plasma
`ers , weatherability additives . Examples of pigments include ,
`PECVD process may comprise , for example , octamethylcy - 30 but are not limited to , carbon black , colored organic pig
`clotetrasiloxane ( D4 ) , tetramethyldisiloxane ( TMDSO ) ,
`ments , and metal oxide pigments ; while suitable dyes
`hexamethyldisiloxane ( HMDSO ) , vinyl - D4 or another vola -
`include various direct dyes , acidic dyes , basic dyes , and / or
`tile organosilicon compound . The organosilicon compo

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