text:
|Publication number||US5750234 A|
|Application number||US 08/660,908|
|Publication date||May 12, 1998|
|Filing date||Jun 7, 1996|
|Priority date||Jun 7, 1996|
|Also published as||CA2257872A1, EP0907501A1, EP0907501A4, US6349754, WO1997046377A1|
|Publication number||08660908, 660908, US 5750234 A, US 5750234A, US-A-5750234, US5750234 A, US5750234A|
|Inventors||John R. Johnson, Diana M. Mercier|
|Original Assignee||Avery Dennison Corporation|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (8), Referenced by (103), Classifications (36), Legal Events (8)|
|External Links: USPTO, USPTO Assignment, Espacenet|
This invention relates to the use of dry paint transfer techniques for producing an interior automotive skin material for coating functional interior components that cover instrument panels, door panels, and the like. More particularly, the invention relates to the production of an extremely low gloss dry paint transfer sheet that can be made into complex-shaped components for automobile interiors by conventional thermoforming techniques. The invention is environmentally sensitive in that the skin product is recyclable and avoids solvent evaporation problems associated with spray painting such interior automotive skin materials.
Automotive interiors present a unique set of problems in the painting of certain components. For example, automobile dashboards can be exposed to high levels of heat and ultraviolet radiation which can detrimentally affect their appearance over time. Furthermore, in order to avoid causing glare, which can be annoying to passengers and dangerous to the driver of an automobile, low gloss finishes for components such as dashboard skin components are desired.
While vinyl compounds such as PVC have been used for such applications, such compounds require large amounts of heat and light stabilizers to avoid adverse weathering effects. Such stabilizers have a tendency to migrate out of the coating material and form a haze over the automobile interior, resulting in an undesirable phenomenon known as "fogging." Furthermore, because they are difficult to recycle, there is a desire to minimize the use of PVC components. A low gloss non-PVC material that is cosmetically acceptable, color stable and durable is desired for use in forming skin components for automotive interiors.
Other skin components for automotive interiors have used urethane paint coats, sometimes with filler particles to lower the gloss level of the outer surface. However, these paint systems are principally thermosets applied by conventional automotive spray paint techniques and therefore contribute to the environmental problems of non-recyclability and solvent emissions.
Briefly, one embodiment of this invention comprises a plastic part for use as an interior automotive skin component which comprises a thermoplastic resinous base coat/clear coat paint film bonded to the outer surface of a thermoplastically formable semi-rigid resinous backing sheet. The base coat/clear coat paint film is preferably formed by dry paint transfer techniques in which the clear coat layer and pigmented base coat layer are first coated on a polyester carrier and dried. The base coat/clear coat paint film is then transferred from the carrier and laminated to the backing sheet on which the clear coat layer forms a low gloss protective outer surface. The clear coat material preferably comprises an alloy of an acrylic resin and a fluoropolymer resin, preferably polyvinylidene fluoride. The low surface gloss of the outer clear coat is produced by a uniformly dispersed fine particulate filler such as silica in combination with coating the clear coat layer on a low gloss matte carrier. This combination produces a desirable tactile feel to the low gloss surface owing to the presence of microroughness in the filler-enhanced outer clear coat and the matte carrier. The surface gloss also is produced uniformly across the surface of the skin material with minimal gloss variation. The composite laminate is thermoformable to a three-dimensionally shaped contour in which the outer clear coat has an extremely low 60 degree gloss level of less than about 15 gloss units, more preferably less than about 10 gloss units. In one embodiment, the gloss level can be less than about 2 gloss units.
The invention thus provides a non-PVC thermoplastic contoured interior automotive skin component that avoids the recycling problems and heat and light stabilizer problems of vinyl coated interior parts. The invention also provides an automotive interior part with a desirable glare-reducing extremely low gloss finish that can be made by a reasonably high speed and cost effective process. The product also has good mar and abrasion resistance, stain and other chemical resistance, and resistance to UV degradation required for these functional automotive skin products.
These and other aspects of the invention will be more fully understood by referring to the following detailed description and the accompanying drawings.
FIG. 1 is a schematic cross-sectional view illustrating the components of one embodiment of a dry paint transfer laminate for providing an interior automotive skin material according to this invention;
FIG. 2 is a schematic cross-sectional view illustrating a process for producing the layers of the dry paint transfer laminate during its production; and
FIG. 3 is a schematic cross-sectional view illustrating an alternative form of the invention which includes a composite foamed substrate.
The decorative dry paint transfer laminate of the present invention is made by a multi-stage coating process. FIGS. 1 and 2 are schematic cross-sectional views illustrating the layers of a low gloss dry paint transfer laminate. FIG. 1 illustrates the layers of the transfer laminate as ready to be thermoformed into a desired three-dimensional contoured shape for forming an automotive skin component. This component is the type to be applied to a substrate in a process for manufacturing a functional interior component for covering mechanical parts of the automotive interior such as instrument panels, door panels and the like. These skin components because of their functional nature are to be distinguished from the purely aesthetic interior trim parts which do not have the same rigorous automotive specifications for wear resistance, stain resistance and UV resistance, for example. FIG. 2 illustrates the layers of the transfer laminate during its production. This transfer sheet includes first and second color coat layers 12 and 14. A low gloss top coat 16 is bonded to the first color coat by intervening first and second tie coats 18 and 20. The top coat, also referred to as an outer clear coat, provides a protective outer coating for the underlying color coats. The color coats are bonded to a backing sheet 22 by a size coat 24. While the color coats generally described are solid color coats, it is clear that patterned color coats may also be used. For example, a wood grain color coat may be desirable in some applications.
During its production, the various layers are applied in reverse order on a temporary casting sheet 26. In a preferred embodiment, the casting sheet has a matte finish such as that provided by a chemical matte layer applied as a low gloss coating to a baseweb, or a matte polyester baseweb in which the low gloss surface is produced by embossing techniques. The top coat is applied to the casting sheet, followed by the application of the first and second tie coats and the first and second color coats, in that order.
The backing sheet 22, which has been provided with a size coat, is then heat laminated to the second color coat. The temporary casting sheet with its matte release layer is then stripped from the transferred laminate to expose the outer clear coat layer as a surface finish for the composite product, producing the paint film composite structure shown in FIG. 1. The paint film composite is then thermoformed to a desired three-dimensionally contoured configuration which produces the desired low gloss level of the finished product.
In another embodiment, the paint film is laminated to a sheet of a foamed polymeric material either by heat lamination or by the use of an adhesive. The foamed layer can comprise one or more foamed thermoplastic olefins (TPO), including a foamed polypropylene. A thin layer of a foamed polyolefin can be used to separate the foamed substrate material from the upper paint coatings. Then the combined sub-layers and paint film can be thermoformed to the desired shape. The contoured laminates made by the present invention can be used directly as interior automotive skin components or they can be bonded to underlying structural supporting substrates by known techniques.
The low gloss finish for the laminate is achieved by the use of a top coat which preferably contains uniformly dispersed filler particles. In the preferred embodiment, silicon dioxide is used as the filler. Enough filler should be added to the clear top coat to control the desired low gloss level.
One surprising discovery of the present invention is that by using a top coat that contains a dispersion of filler particles, a low gloss dry paint transfer laminate can be made after casting the outer clear coat on a high gloss casting sheet. When a high gloss casting sheet is used, the smooth finish of the casting sheet is temporarily imparted to the top coat, making the dry paint transfer laminate appear glossy when the casting sheet is removed. However, upon applying the dry paint transfer laminate to the backing sheet 22 and thermoforming the composite of the transfer sheet and backing sheet into the desired shape of the finished article, the previously high gloss finish is reduced to a low gloss finish.
While a low gloss finish can be achieved even with the use of a high gloss casting sheet, in a preferred embodiment the low gloss surface of the dry paint transfer laminate is further enhanced by using a temporary casting sheet having a matte (low gloss) finish. For example, a matte polyester baseweb can be used as the casting sheet. In another embodiment, a matte finish temporary casting sheet is made by coating a polyester casting sheet with a thermoset chemical matte release coat. Use of a temporary casting sheet with a matte coat causes the low gloss finish of the temporary casting sheet to be replicated onto the outer surface of the top coat which is coated onto the matte surface. When a matte casting sheet is used, the outer clear coat surface of the dry paint transfer laminate has a matte finish, even before the laminate has been thermoformed. Because increased levels of filler can make the top coat soft, and therefore somewhat susceptible to scratching and marring, in a preferred embodiment the desired low gloss level in the outer clear coat is achieved by a proper balancing of the use of a matte finish casting sheet and a top coat containing the finely divided filler particles. A much lower amount of filler is used in the outer clear coat layer when compared with casting on a high gloss carrier to achieve the same or similar low gloss level. By using the lower filler content, mar and abrasion resistance of the clear coat are improved, as previously mentioned.
In one embodiment the outer clear coat solids comprise the combination of polyvinylidene fluoride (PVDF) and an acrylic resin. The amount of filler contained in the top coat formulation can be less than about ten parts by weight of filler per one hundred parts by weight of total resin binder contained in the polymeric outer clear coat formulation. If higher levels of filler are added, the top coat generally becomes too soft, making it susceptible to scratching and marring. In a more preferred embodiment, less than about five parts filler per one hundred parts resin binder are used in the top coat, by weight, based on the total solids present in the filler/binder component of the clear coat composition. Such a combination provides exceptional scratch and mar resistance while providing an attractive, low gloss finish. The preferred low gloss is produced when casting these filler-enhanced coatings on matte carrier sheets, as described below.
Once formed, the dry paint transfer laminate of the present invention can be applied to a substrate by conventional thermoforming techniques to make a shaped article having the desired low gloss. Once thermoformed, the article has a low gloss finish that is very durable. Articles formed in this way are not only scratch and mar resistant, but they are also resistant to high temperatures and ultraviolet exposure, making them ideal for use in dashboards and other components for automotive interiors. A low gloss finish such as that provided by this invention is especially desirable for automotive dashboards because the low finish reduces glare. Furthermore, because the dry paint transfer sheet does not include PVC, it is easier to recycle such components. Finally, unlike the PVC products that are typically used to coat automobile interior components, the components made using dry paint transfer sheets of the present invention will greatly reduce fogging.
In one embodiment, a matte polyester baseweb 26 is used as the temporary matte casting sheet. This baseweb can be 98 gauge polyester sheet, the surface of which has been embossed by an embossing roll during the extrusion process for making the casting sheet in order to impart a matte finish to its surface. Another matte polyester casting sheet can be a polyester carrier having a measured 60 degree gloss reading of 16.8 gloss units, in which the matte polyester carrier is part of the 2000 Series Hoechst casting sheets.
In another embodiment, a process for making a low gloss casting sheet includes coating a matte release coat in thin film form onto the surface of a flexible, foldable, heat-resistant, substantially inelastic, self-supporting temporary casting sheet. The casting sheet is preferably a 92 gauge, high gloss, oriented polyester casting sheet such as Mylar (a trademark of DuPont), Hoechst Celanese Hostaphan 2000 polyester film, or the like.
The casting sheet is coated with the matte release coat by conventional methods such as by roller coating or gravure printing processes. The preferred matte release coating composition is a thermosetting resinous material which, when exposed to heat during a drying step, becomes crosslinked and permanently bonded as a surface film adhered to the casting sheet. The solids contained in the matte release coat preferably include, as a principal component, one or more crosslinking agents to provide good adhesion of the dried crosslinked coating to the polyester casting sheet.
In one embodiment, the matte release coat formulation includes a primary crosslinking resin such as a vinyl resin that bonds to the casting sheet. A suitable vinyl resin is a medium molecular weight vinylchloride-vinylacetate resin known as VAGH, described in more detail in Example 1 below. This vinyl resin can be present in an amount up to about 20% of the total solids in the matte release coat. In addition, the matte release coat can include a secondary crosslinking resin to improve release of the top coat from the matte release coat. In one embodiment, the secondary crosslinking resin can be an acrylic modified alkyd resin such as the resin described in more detail in Example 1. This secondary crosslinking resin comprises from about 1% to about 15% of the total solids of the matte release coat. The matte release coat further includes a suitable catalyst for accelerating the crosslinking process, typically comprising from about 1% to 2% of the total solids in the matte release coat.
The resinous components of the matte release coat composition are mixed with suitable solvents for application to the casting sheet. In one embodiment, the resins are mixed with a primary resin solvent such as methyl isobutyl ketone (MIBK) which comprises about 65% to about 85% of the total solvent in the formulation. A secondary resin solvent such as isopropyl alcohol (IPOH) is useful in retarding crosslinking of the resins in solution. The secondary resin solvent preferably comprises from about 5% to about 20% of the total solvent.
The matte release coat formulation is prepared by dissolving the primary crosslinking resin in the primary and secondary resin solvents by mixing, and then adding the secondary crosslinking resin together with a primary matting agent, preferably in the form of a filler comprising a fine particulate inert inorganic material. In one embodiment, the filler comprises aluminum silicate with an average particle size of about 4.8 microns. The filler contained in the formulation comprises up to about 25% of the total solids in the matte release coat. The fine particulate filler is thoroughly dispersed in the resin and resin solvent blend, preferably under elevated temperatures from about 100° to about 120° F.
When the matte release layer dries and crosslinks, it forms a chemical matte coating on the surface of the carrier sheet. The matte surface is controlled by the amount and particle size of the filler. The fine particles project through the dried exterior surface of the matte release coat to form, on a microscopic scale, a surface with a microroughness that transfers to the surface of the dried top coat a replicated microroughness that produces light-scattering, resulting in a low surface gloss on the top coat. Since the matte finish is bonded to the casting sheet in order to impart a microroughness to the top coat, it does not form a part of the finished dry paint transfer sheet. Therefore, the inclusion of vinyl compounds in the matte finish does not adversely affect the recyclability of the products using the dry paint transfer sheet of the present invention.
The matte release coat formulation also includes a release agent to enhance the release of the casting sheet and its matte release coat from the top coat after the dry paint transfer sheet has been completed. The release agent preferably includes a wax component such as a polyethylene wax which melts at elevated temperatures to allow easy hot release of the release coat. Such a wax component is suspended in the matte release coat at normal temperatures. In its suspended or particulate form, the wax acts as a matte agent to enhance transfer of the low surface gloss to the top coat. A preferred polyethylene wax is Shamrock S-381-N1 (described in Example 1 below), which has a melting point of about 206° F. Stripping of the release-coated carrier is preferably carried out at temperatures more than about 80° F. above the melting point of the wax, to enhance release properties. The wax, which melts at relatively higher temperatures as it dries, can have a crystalline or semi-crystalline structure. At relatively lower temperatures it is believed to crystallize and reform particles which affect the matte transferred to the top coat. In one preferred form of the matte release coat formulation, the polyethylene wax comprises from about 12% to about 25% of the solids contained in the matte release coat.
The release agent contained in the matte release coat formulation further includes a silicone resin component which combines with the polyethylene wax to enhance free release of the clear coat from the matte release coat at elevated temperatures. In one embodiment, the silicone resin comprises from about 2.5% to about 25% of the solids contained in the matte release coat formulation. Release is improved and lower gloss is transferred when the wax and silicone resin are used in combination in the matte release coat.
The casting sheet containing the matte release coat is dried by conventional means such as by an impinging air oven operated at a temperature from about 200° F. to about 250° F., for a sufficient time for drying and crosslinking the matte release coat. Once sufficiently crosslinked, the matte release coat becomes permanently bonded to the casting sheet. Preferably, the matte release coat is coated and dried to produce a coat weight (dry) from about 6 to about 12 g/m2. This chemical matte casting sheet has a measured 60 degree gloss reading of 8.7 gloss units. After the matte release coat has been applied to the casting sheet, a top coat layer can then be applied.
The top coat is cast to the surface of the casting sheet by conventional methods such as by a reverse-roll coating process. The top coat is preferably a transparent clear coat, although it can be pigmented. If pigmented, it is preferred that the pigmentation be at a sufficiently low level that underlying paint coats are visible through the top coat.
Preferably, the top coat is a thermoplastic and thermoformable lacquer formulation that produces a dry film form, durable coating having desired properties of hardness and abrasion resistance, along with UV resistance. In one embodiment, the top coat is formulated from a thermoplastic synthetic resinous coating which replicates the microroughness from the matte release coat to produce the desired low gloss surface for the finished product. The top coat preferably comprises a blend of a thermoplastic fluorinated polymer and a thermoplastic acrylic resin as its principal components. The fluorinated polymer component is preferably a thermoplastic fluorocarbon resin, such as polyvinylidene fluoride (PVDF). The fluorinated polymer resin also can include copolymers and terpolymers of vinylidene fluoride or polyvinyl fluoride, or mixtures thereof. One thermoplastic fluorocarbon useful as the top coat is the PVDF known as Kynar, a trademark of Elf Atochem. This polymer is a high molecular weight polymer which provides a useful blend of durability and chemical resistance properties. The PVDF component preferably comprises from about 40% to about 70% by weight of the total PVDF and acrylic resin solids present in the top coat.
The acrylic resin component of the top coat can be a polymethylmethacrylate or a polyethylmethacrylate resin, or mixtures thereof, including methacrylate copolymer resins, and minor amounts of other comonomers. The top coat also can include minor amounts of block copolymers and other compatibilizers to stabilize the blended PVDF and acrylic resin system and provide compatibility with the underlying paint film.
In one embodiment, a principal component of the acrylic resin contained in the top coat is a medium molecular weight polyethylmethacrylate resin such as Elvacite 2042, a trademark of DuPont. This acrylic resin clarifies the top coat, hardens the top coat, and improves adhesion to the underlying color coats. In its preferred form, the acrylic component comprises from about 30% to about 60% of the total solids contained in the top coat formulation.
The top coat also includes a finely divided particulate filler which helps provide the matte finish to the finished product. Preferably, silicon dioxide is used as the filler. In the preferred embodiment, the silicon dioxide filler, sold under the trademark TS 100 from the Degussa Corporation, is dispersed uniformly in the clear coat material. This filler has a particle size range from about one to about nine microns with an average particle size of about four to five microns. The filler is preferably contained in the clear coat material in an amount below about ten parts filler per 100 parts binder resin by weight, based on the total solids present in the mixture. The preferred filler level is less than five parts and more preferably less than about two parts per one hundred parts resin.
The PVDF and acrylic based top coat formulation can be prepared as a dispersion of the PVDF and a solution of the acrylic resin. In one embodiment, the top coat formulation is prepared by mixing the acrylic resin with a suitable organic solvent and applying heat to dissolve the resin. The mixture is then allowed to cool sufficiently before adding the PVDF component and filler, so that the PVDF will not dissolve, but will be maintained as a dispersion with the filler in the acrylic-solvent based mixture. By maintaining the PVDF component as a dispersion in the top coat, solvent evaporation during drying of the top coat can be improved. Suitable solvents and the amounts of solvent used are set forth below in Example 1.
Other minor components of the top coat formulation can include UV absorbers such as Tinuvin 234, a benzotriazole UV absorber available from Ciba-Geigy, comprising up to about 3% of the total solids, and a dispersing agent such as Solsperse 17000 (trademark of ICI Americas) useful for reducing the viscosity of the dispersion coating. The dispersing agent preferably comprises up to about 4% of the PVDF component.
Once cast, the top coat is dried by conventional means. Preferably a multiple stage impinging air oven is used to dry the top coat. The different drying zones of the oven can be controlled at different temperatures depending upon the drying characteristics of the top coat. The top coat is preferably dried and fused at an oven air temperature of about 350° F. for about 2 minutes to form a durable clear coat on the matte release film. The preferred dry film thickness of the top coat is about 0.3 to about 1.5 mils.
One or more tie coats are then applied to the top coat. In this embodiment, a single tie coat is applied by a gravure printing process. The tie coat improves the bond between the top coat and the underlying color coats. Preferably, an acrylic resin tie coat is used, and the preferred acrylic resin is a solvent-based Elvacite 2042 adhesive resin formulation. The tie coats are preferably dried in a multiple stage impinging air oven at a temperature of about 200° F. for about 20 seconds. If more than one tie coat is provided, the first tie coat is fully dried before the second tie coat is applied. Each tie coat is preferably about 0.1 mils thick when dry.
One or more color coats are then applied to the dried tie coat to provide the desired color to the transfer sheet. Preferably, two color coats are applied by a gravure printing process. Each color coat preferably comprises a thermoplastic and thermoformable polymeric binder material containing uniformly dispersed pigments. The preferred color coat is made of a coating containing an acrylic resin that contains a sufficient level of pigment to provide the desired color for the finished product and also to improve the finished product's resistance to UV degradation. A liquid cast, weatherable color coat containing an acrylic polymer is preferred. In one embodiment, the color coat contains a blend of PVDF and an acrylic resin, such as polymethylmethacrylate or polyethylmethacrylate. The ratios of PVDF to acrylic resin solids contained in the blend or alloy are similar to those described previously for the top coat formulation. The color coats are dried in a multiple stage impinging air oven at a temperature of about 200° F. for about 20 seconds. The first color coat is hardened before the second color coat is applied. Each layer of color coat is cast to a thickness of about 0.1 mils (dry).
The backing sheet preferably comprises a thermoplastic and thermoformable polymeric material in thin flexible sheet form. The backing sheet is preferably a semi-rigid polymeric sheet from about 10 to 60 mils in thickness, the preferred thickness being about 20 to 30 mils. A thermoplastic polyolefin (TPO) sheet is most preferred. This backing sheet is produced from a TPO resin sold under the name KS-350 which is supplied by Montel Corp. of Wilmington, Del. A preferred polyolefin material for the backing sheet comprises polypropylene.
A size coat is bonded to the backing sheet as a bonding layer for adhering the backing sheet to the dry paint transfer film. The size coat comprises any of various suitable coating compositions to provide adhesion of the dry paint film to the backing sheet. The size coat is preferably made from an adhesive coating composition capable of bonding to the backing sheet. A preferred size coat comprises copolymers of PMMA and an olefin. Such a size coat formulation is sufficient for providing a good bond between the dry paint sheet and the substrate. Although a CPO size coat can be used, non-chlorinated size coats are preferred when compared with CPO because weatherability is better.
The dry paint transfer laminate is then transferred to the backing sheet by dry paint transfer lamination techniques. The laminate, while supported by the carrier sheet, is bonded to a surface of the backing sheet which has preferably been coated with a bonding layer of a size coat. A preferred transfer lamination process is described in the FIG. 6 embodiment of PCT Publication WO 88/07416 to Spain et al., which is incorporated herein by this reference. The temporary casting sheet is then stripped from the dry paint laminate. A series of water-cooled chill rollers produce a controlled temperature reduction in the dry paint laminate so as to cool it to a temperature in the range from about 295° to about 340° F. Once cooled to within this range, the temporary casting sheet is stripped from the paint sheet. The preferred stripping temperature is 308° F. If the temperature stays too high, flowability of the paint sheet can cause the microroughness imparted by the matte finish of the temporary casting sheet to smooth out. The temperature drop also enhances the free removal of the paint sheet from the casting sheet. When the matte release coated casting sheet is used, the matte release coat, which has been crosslinked and permanently bonded to the casting sheet, remains adhered to the carrier sheet during the stripping process.
The dry paint transfer sheet (in the form of the laminate shown in FIG. 1) can then be applied to a substrate and thermoformed into the desired shape. The optimum thermoforming temperatures of such sheets are about 330° F. Such a sheet temperature is achieved by a 25 second dwell time in a 500° F. oven. The elongation ranges for the dry paint transfer sheets of the present invention are between about 50% and 150% during thermoforming. The elongation will depend in part on the geometry of the finished product, the depth of draw, and other factors.
If the dry paint transfer sheet is cast on a high gloss temporary casting sheet, the low gloss finish will not be fully realized until after the thermoforming process, which causes a large decrease in gloss level. For dry paint transfer sheets cast on a matte finish casting sheet, the gloss will not change significantly, but will be reduced during thermoforming.
Surface gloss can be measured by various techniques such as ASTM designation D 3679-86, 5.11. A Dorigon gloss meter manufactured by HunterLab or a Byk-Malinckrodt gloss meter are the preferred instruments used to provide instrument precision gloss measurements. Using this surface gloss measurement technique, the outer surfaces of the top coat layer of the dry paint transfer sheets produced according to the present invention have 60 degree gloss levels of less than about 15 gloss units. Preferably, the 60 degree surface gloss is less than about ten gloss units, and more preferably 60 degree surface gloss levels are as low as two gloss units.
The finished product also can be textured in one of several processes to provide a tactile feel to the surface. Texturing can be carried out by an embossing roll or by a textured vacuum-forming tool in which the product being shaped is drawn into the vacuum-forming tool. The texturing can add a grain pattern or the like, but gloss levels are not appreciably reduced. Texturing in a vacuum forming tool is desirable because the product readily replicates the mold and preserves the integrity of the pattern.
In addition to providing a durable low gloss finish for use in producing components for automobile interiors, other advantages of the present invention include the ability for auto makers to eliminate the use of spray coatings on interior components. The dry paint transfer sheets of the present invention can be applied directly to such components during thermoforming, resulting in the elimination of the emission of volatile organic compounds which are released when using conventional spray painting equipment.
The invention will be further explained by the following examples.
A matte release coat was formulated from the following components:
______________________________________ Component Parts______________________________________Composition 1: Methyl isobutyl ketone (MIBK) 38.3 Isopropyl alcohol (IPOH) 6.7 VAGH 4.8 ASP400 44.3 Lankyd 13-1245 5.9 100.0Composition 2: Methyl isobutyl ketone 56.7 Isopropyl alcohol 9.0 VAGH 15.1 Lankyd 13-1245 19.2 100.0Release Coat: Composition 1 41.8 Composition 2 21.1 SR107 1.2 S381-N1 5.0 MIBK/IPOH Blend (85/15) 21.4 Cycat 4040 3.8 Cymel 303 5.7 100.0______________________________________
1. VAGH is a medium molecular weight, partially hydrolyzed vinyl chloride-vinyl acetate resin (approximately 90% vinyl chloride, 4% vinyl acetate and a hydroxyl content of 2.3%) sold by Union Carbide, Somerset, N.J.
2. ASP400 is an aluminum silicate of average particle size 4.8 microns made by Engelhard Corp., Edison, N.J., and sold by Jensen-Souder, Itasca, Ill.
3. Lankyd 13-1245 is an acrylic alkyd solution available from the Akzo Corp. of East Saint Louis, Ill.
4. SR-107 is a silicone resin manufactured by General Electric, Waterford, Conn., and sold by Fitzchem, Chicago, Ill.
5. S381-N1 is a polyethylene wax sold by Shamrock Chemicals Corp., Newark, N.J.
6. Cycat 4040 is a para toluene sulfonic acid catalyst (40% by weight in isopropanol) sold by American Cyanamid Co., Wallingford, Conn.
7. Cymel 303 is a liquid hexamethoxy-methylmelamine crosslinking agent sold by American Cyanamid.
Composition 1 was produced by dissolving the VAGH resin in a blend of MIBK and IPOH by mixing in a Cowles mixer and then adding the Lankyd 13-1245 and ASP400 while mixing. This mixture was then sandmilled at a temperature of about 110° F. to disperse the ASP400.
A low gloss clear top coat was formulated from the following components:
______________________________________Component Parts______________________________________Elvacite 2042 Solution 52.72Tinuvin 234 0.64Solsperse 17000 0.08TS 100 0.20Kynar 500 Plus (PVDF) 20.76Cyclohexanone 7.68Exxate 700 7.68Butyrolactone 10.24 100.00______________________________________
The Elvacite 2042 Solution had the following formulation:
______________________________________ Component Parts______________________________________ Elvacite 2042 21.20 Exxate 700 24.82 Cyclohexanone 23.64 Butyrolactone 30.34 100.00______________________________________
8. Elvacite 2042 is a polyethylmethacrylate resin with a weight-average molecular weight of 300,000, sold by DuPont, Wilmington, Del.
9. Tinuvin 234 is a 2-(31,51,bis(1-methyl 1-phenylethyl)-21 hydroxyphenyl) benzotriazole U.V. light stabilizer sold by Ciba Geigy, Hawthorne, N.Y.
10. Solsperse 17000 is a polymeric fatty ester dispersing agent sold by ICI Americas Inc., Wilmington, Del.
11. TS 100 is a silicon dioxide filler with an average particle size of 4 microns, with a range from about 1 to 9 microns, sold by Degussa Corporation.
12. Kynar 500 is a polyvinylidene fluoride polymer sold by Elf Atochem, Philadelphia, Pa.
13. Exxate 700 is a high boiling point acetate solvent sold by Exxon Chemicals.
14. Butyrolactone is used for solubility of the acrylic resin and is a high boiling point Ketone
In this embodiment, the filler particles (TS 100) comprised 0.63 parts per one hundred parts resin binder by weight based on the total solids of the PVDF/acrylic resinous binder contained in the top coat formulation.
The Elvacite 2042 Solution was first blended by dissolving the Elvacite 2042 in the solvents Exxate 700, cyclohexanone and butyrolactone.
The Elvacite 2042 Solution, Solsperse 17000 and Tinuvin 234 were then dissolved in the cyclohexanone solvent at a temperature of 130° F. and allowed to cool to room temperature. The PVDF was then dispersed in the resin solution with the TS 100 using a 14 inch Cowles blade at 1800 RPM. The temperature of the PVDF dispersion was kept below 110° F. to avoid gelation of the dispersion. Next, the remaining solvents were preblended before mixing into the PVDF dispersion. In this embodiment, the top coat was not pigmented.
A first acrylic tie coat was prepared from the following components:
______________________________________Component Parts______________________________________Toluene 45.00N-Propyl Acetate 45.00Elvacite 2042 9.82Tinuvin 234 0.18 100.00______________________________________
A second acrylic tie coat used in this example primarily consisted of methylmethacrylate and a smaller amount of cellulose acetate propionate available from Gibraltar Chemical Co. of South Holland, Ill.
An acrylic color coat was prepared by mixing the following components:
______________________________________Component Parts______________________________________Color Coat Vehicle 69.11Metallic Color Coat Vehicle 9.68BASF 6930 Blue Dispersion 3.69Perylene Maroon Dispersion 4.40Black Dispersion 13.02Thinner 0.10 100.00______________________________________
The color coat vehicle was prepared by mixing the following components:
______________________________________Component Parts______________________________________Toluene 37.70Methyl Propyl Ketone 37.70Isopropyl Alcohol 8.30Elvacite 2021 13.10CAP 482-0.5 Cellulosic 3.10 100.00______________________________________
The metallic color coat vehicle was prepared by mixing the following components:
______________________________________Component Parts______________________________________Elvacite 2021 18.30CAP 482-0.5 Cellulosic 4.60Sanduvor 3050 0.45Sanduvor 3206 0.45Toluene 34.30Methyl Propyl Ketone 34.30Isopropyl Alcohol 7.60 100.00______________________________________
15. Elvacite 2021 is a methylmethacrylate from DuPont.
16. Cap 482-0.5 is a cellulose acetate propionate available from Eastman Chemical Products, Kingsport, Tenn.
17. Sanduvor 3050 and 3206 are an oxalamide derivative and an oxazoline, respectively, both supplied by Sandoz Chemicals, Charlotte, N.C.
A size coat was prepared from the following components:
______________________________________Component Parts______________________________________Rohasol PM 555 53.16Cyclohexanone 23.88Elvacite 2042 7.96Methylisobutylketone 15.00 100.00______________________________________
18. Rohasol PM 555 is an organic emulsion of copolymers of methacrylic esters and olefins available from the Rohm Tech corporation of Malden, Mass.
The Elvacite 2042 is first added under agitation to the cyclohexanone until it is in solution. The PM 555 and methylisobutylketone are then added.
Preparation of a Dry Paint Transfer Sheet
The matte release coat was gravure coated with a 100 HK gravure cylinder pattern at a coat weight (dried) of 3 g/m2 onto a 92 gauge oriented gloss polyester casting sheet (Hostaphan 2000, available from Hoechst Celanese, Greer, S.C.) at about 100 feet per minute and dried and crosslinked in a 20 foot impinging-air oven at an air temperature of 250° F. (web temperature approximately 220° F.).
Next, the top coat was coated at a coating weight (dried) of 40 g/m2 onto the dried matte release coat by a reverse-roll coater at 40 feet per minute or less. The top coat was dried and fused in a 120 foot three-zone impinging air oven with the air temperatures in the three zones being 250° F., 300° F., and 350° F. This formed a transparent clear coat having a dry film thickness of 1.0 mil on the matte release coat of the casting sheet.
To minimize web shrinkage and avoid distortion of the casting sheet, web tension was maintained below 0.8 lbs/linear inch of web width through the drying ovens. The dried, coated casting sheet was wound as a roll, removed from the first coater and set up on the unwind station of a second coater. The clear-coated side of the casting sheet was then gravure printed at a speed of 100 feet per minute with a series of two tie coats, and two color coats. The drying oven temperature was 200° to 225° F. The dried coat weight of the tie and color coats ranged from 3-5 g/m2.
The size coat was then cast onto a separate 92 gauge oriented gloss polyester casting sheet by a reverse roll coating process at a coat weight (dried) of about 10 to 30 g/m2 and dried in an impinging-air oven at an air temperature of about 200° F. for about two minutes. The dried size coat was heat laminated to a 20 mil TPO backing sheet, followed by removing the casting sheet. The size coat of the backing sheet was then heat laminated to the second color coat and the composite laminate was stripped from the casting sheet.
The composite laminate was then thermoformed at a sheet temperature of 330° F. This temperature was achieved with a 25 second dwell time at 500° F. Prior to thermoforming, the outer clear coat had a 60 degree gloss value of 9.9 gloss units. After the above dry paint transfer sheet was thermoformed, gloss measurements were taken, and a 60 degree reading of 8.0 gloss units was achieved using the HunterLab Dorigon gloss meter. The finished clear coat had good mar and scratch resistance as measured by General Motors Specification No. GM6073M scratch test.
A low gloss clear top coat was formulated from the following components:
______________________________________Component Parts______________________________________Elvacite 2042 8.44Tinuvin 234 0.48Solsperse 17000 0.06TS 100 2.41Kynar 500 Plus (PVDF) 15.67Cyclohexanone 21.88Exxate 700 22.36Butyrolactone 28.70 100.00______________________________________
This top coat formulation was applied to a 2 mil high gloss polyester casting sheet and dried in an air convection oven using conventional techniques. The tie coats, color coats, size coat and backing sheet were applied as set forth in Example 1. The resulting dry paint transfer sheet had a fairly high gloss initially. A 60 degree gloss measurement showed a reading of 75 gloss units. However, after thermoforming, the gloss had decreased to a reading of 1.8 gloss units at 60 degrees.
Dry paint transfer sheets according to Examples 1 and 2 were prepared in which the amount of TS 100 filler in the top coat was varied as illustrated in the following table. The amount of TS 100 is expressed as parts of TS 100 per hundred parts of resin solids (PVDF and acrylic combined). The top coats were applied to three different casting sheets: a chemical matte, as set forth in Example 1; a matte polyester comprising a Hoechst 2000 Series casting film; and a high gloss polyester as set forth in Example 2. These dry paint transfer sheets were thermoformed and then tested for gloss using the Dorigon gloss meter. The 60 degree gloss measurements are provided in the following table.
______________________________________ Chemical Matte High GlossTS 100 Matte Polyester Polyester______________________________________0.63 9.9 36.9 57.11.35 6.7 35.0 46.52.51 5.6 17.9 26.84.66 3.9 10.6 22.97.13 3.4 5.8 11.310.00 2.8 5.5 6.8______________________________________
Dry paint transfer sheets were prepared in which the outer clear coat material contained no filler particles. The laminate was produced according to the methods of Examples 1 and 2, and the clear coat was cast in contact with three separate types of basewebs similar to those used in Example 3: (1) a chemical matte release coated casting sheet; (2) a matte polyester casting sheet; and (3) a high gloss polyester casting sheet.
The unfilled clear coat outer layer was measured for 60° gloss following thermoforming with the following results:
______________________________________Chemical Matte High GlossMatte Polyester Polyester______________________________________14.0 38.3 75.2______________________________________
The test results show that a generally linear relationship between increase in filler level and reduction of gloss was produced for clear coats cast on each casting sheet.
Generally, the conclusion was that low gloss laminates with good abrasion resistance can be produced with no filler particles but for extremely low gloss laminates having a 60° gloss level below about 10 gloss units, it is preferred to add the filler particles to the coating. In addition, the filler particles in combination with casting on a matte carrier sheet, particularly a chemical matte carrier, produce a surface microroughness which transfers a desirable tactile feel to the end-product in addition to the low gloss level.
A laminate was produced with an unfilled outer clear coat layer comprising a PVDF homopolymer alloyed with an acrylic resin. The PVDF homopolymer was supplied by Ausimont, U.S.A., and available under the designation Mylar 5000 LG. This particular PVDF resin has a high molecular weight and an inherently low gloss. The PVDF material was alloyed with an acrylic resin to produce a dispersion PVDF/acrylic clear coat material which was cast on both the chemical matte and high gloss polyester basewebs, laminated to a TPO backing sheet and then thermoformed. Sixty degree gloss measurements were 5 gloss units for the outer clear coat on the chemical matte baseweb and about 50 for the high gloss polyester carrier. Because of the extremely low gloss produced by contact with the chemical matte baseweb, this inherently low gloss high molecular weight PVDF resin, enhanced with the filler particles uniformly dispersed, can achieve exceedingly low gloss levels.
Although the invention has been described in relation to a dry paint film composite laminate having a low gloss base coat/clear coat paint finish with an underlying thermoplastic and thermoformable solid polymeric backing sheet, other embodiments also are contemplated. For instance, it may be possible to carry out the invention with the outer clear coat only, without use of an underlying color coat. In this embodiment the underlying backing sheet would need a level of weather resistance and would incorporate the desired decorative pigment system for an appropriate color match. A size coat system having weather resistance would bond the clear coat to the backing sheet.
A further embodiment of an interior automotive skin component was produced without a color coat but having a low gloss outer clear coat highly loaded with UV absorber to protect the underlying CPO bonding layer, according to the following formulation:
______________________________________Component Parts______________________________________Elvacite 2022 Solution 58.51Solsperse 17000 0.08Tinuvin 328 2.49Hylar 5000 LG 18.60Cyclohexanone 6.09Exxate 700 6.09Butyrolactone 8.14______________________________________
The Tinuvin 328, available from Ciba-Geigy Corp., is added to the formulation at a level of about 8 parts per hundred parts resin solids.
After 600 kiloJoules xenon weatherometer exposure, there was a Delta E color difference reading of less than 1.0 for a construction that had the above top coat, and a CPO size coat underneath, next to the TPO. After the same exposure period, clear coats with 25% (2 phr) and 50% (4 phr) of the UV absorber level given above showed color change and brown spotting, which indicated degradation due to UV light. There is also some evidence that indicates that the amount of UV absorber per unit volume is the most important factor in preventing degradation. Accordingly, it is believed that increasing the film thickness from its present 1.0 mil level may improve UV results, along with increasing the amount of UV absorber to above about 6 phr. A conclusion is that such a construction, with no color coat, can be used in interior automotive applications.
A further embodiment of the invention provides a composite automotive interior skin component having a foamed or cellular substrate preferably comprising a foamed polyolefin polymer. The preferred construction illustrated in FIG. 3 comprises a PVDF/acrylic outer clear coat layer 30, a chlorinated polyolefin (CPO) size coat 32, a 20 mil thermoplastic olefin (TPO), semirigid backing sheet 34, a 100 mil foamed polypropylene substrate layer 36, and a foamed polyethylene/polypropylene substrate layer 38.
A pelletized polypropylene is available from Toray Corp., Front Royal, Va., under the description "APGG." The pelletized polyethylene/polypropylene is available from JSP International, Malvern, Pa., under the designation "APRO." This material is available in a variety of densities, and the density that was used in this example was 10 pounds per cubic foot. The pellets are placed in a mold which forms a cellular matrix structure that fuses to the backing sheet.
A cellular polyethylene/polypropylene substrate layer was thermoformed into the desired shape, after which vacuum holes were drilled into the shaped material and the shaped material was used as a thermoforming tool on which to draw the TPO layer and the cellular polypropylene layer over the previously formed tool.
Alternatively, the invention having a cellular polymeric substrate layer can be produced in other embodiments such as thermoforming the 20 mil TPO backing sheet and 100 mil cellular polypropylene sheet with the PVDF/acrylic clear coat to produce a mold insert, followed by injection molding behind the TPO to form a more rigid strata bonded to the foamed polypropylene layer.
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|U.S. Classification||428/141, 428/149, 428/204, 428/143, 428/331, 428/41.8, 428/156, 428/207, 428/203, 428/42.1, 428/421|
|International Classification||B32B27/18, B32B5/18, B32B27/20, B60R13/02, B32B37/06, B32B3/00, B32B33/00|
|Cooperative Classification||Y10T428/3154, Y10T428/24868, Y10T428/24901, Y10T428/1476, Y10T428/24876, Y10T428/1486, Y10T156/1043, Y10T156/11, Y10T428/24355, B60R13/02, Y10T428/24421, B29K2995/0022, Y10T428/259, Y10T428/24479, B32B5/18, Y10T428/24372|
|European Classification||B60R13/02, B32B5/18|
|Sep 23, 1996||AS||Assignment|
Owner name: AVERY DENNISON CORPORATION, CALIFORNIA
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:JOHNSON, JOHN R.;MERCIER, DIANA M.;REEL/FRAME:008309/0001;SIGNING DATES FROM 19960814 TO 19960907
|Oct 22, 1997||AS||Assignment|
Owner name: CERUS CORPORATION, CALIFORNIA
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:HEI, DEREK J.;ISAACS, STEPHEN T.;CIMINO, GEORGE D.;REEL/FRAME:009198/0996
Effective date: 19971016
Owner name: CERUS CORPORATION, CALIFORNIA
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:HEI, DEREK J.;ISAACS, STEPHEN T.;CIMINO, GEORGE D.;REEL/FRAME:009072/0949
Effective date: 19971016
|Mar 9, 1999||CC||Certificate of correction|
|Nov 9, 2001||FPAY||Fee payment|
Year of fee payment: 4
|Dec 4, 2001||REMI||Maintenance fee reminder mailed|
|Nov 30, 2005||REMI||Maintenance fee reminder mailed|
|May 12, 2006||LAPS||Lapse for failure to pay maintenance fees|
|Jul 11, 2006||FP||Expired due to failure to pay maintenance fee|
Effective date: 20060512

domain: chemistry


MANILA, Philippines — More than two million families consisting of 13 million Filipinos remain literally in the dark as they are still without electricity, the head of the Party-list Coalition in the House of Representatives said yesterday.
Despite efforts by rural electric cooperatives and the National Electrification Administration (NEA) to bring power to remote areas, Rep. Mikee Romero of 1-Pacman said the government’s rural electrification program has not reached 19,000 barangays nationwide.
He said the P5 billion allocated for the program in the last three years had not been enough to electrify the remaining unserved communities, forcing Filipinos in the countryside to make do without electricity. These families continue to use kerosene, paper or wood for their lighting needs, he said.
Romero proposed the allocation of at least P25 billion for the program to serve the 19,000 communities still without power. “On average, each community will need P1.3 million to P1.5 million,” he said.
He also proposed that the NEA be given more autonomy “to do its job, issue and enforce rules, supervise and punish inefficient cooperatives, revoke franchises, generate its own funds, among other powers.”
He said he is confident that given enough budget and authority, the NEA and electric cooperatives would be able to “accomplish their mission of electrifying all communities, including the remotest barangays.”


Deborah Meaden on Verulam in the Morning - Tuesday 16 October
Deborah is best known for her appearances on the BBC Two programme Dragons' Den, where she has agreed investments in the Den of £1,605,000 in 26 businesses over the 6 series in which she has taken part to date. Shee will be interviewed by Phil Richards on Tuesday morning.
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Control & Process Monitoring
We have supplied and upgraded numerous Sterilisation process control and interface systems together with supply of independent monitoring systems.
We have the capability to offer a number of PLC options in both control and monitoring applications and typically supply and service Intouch Wonderware SCADA as an interface.
ISO14937 indicates a requirement for cycles to be reviewed and accepted through equipment and sensors not related to the control of the system.
In the past sterilisation processes would be fitted with a chart recorder with independent sensor inputs from the steriliser. The completed cycle chart could be reviewed manually and used as proof of correct cycle operation.
We have supplied numerous automated independent monitoring systems often replacing the chart recorder on older systems. Our automated monitor reviews every recipe selected tolerance against the running cycle giving live alarms on live cycles and archived "reviewed" cycles indicating out of tolerance deviations and overall cycle summary PASS/FAIL data. This removes the manual review element saving time and potential manual error.
Our automated monitor can be easily integrated into an electronic archiving system* or printed as required to meet the clients archiving systems, *in line with 21CFR Part11 compliance


Introduction to Implementing Neural Network
What do you know about Artificial Neural Network?
A Neural Network is a chain of algorithms that attempts to recognize underlying relationships in an array of data by mimicking the way the human brain operates. Neural Networks can either be biological or artificial, that is they can be formed by biological neurons or artificial neurons. Artificial Neurons can be used to solve AI challenges.
Biological neural networks have influenced the development of artificial neural networks, but they are rarely exact replicas of their biological counterparts. Let us understand the different components of artificial neural networks.
Neuron (Perceptron model)
To start with, one must understand the perceptron model. A perceptron is a single neuron that takes input and produces output. Here is a simple linear perceptron model.
The Linear Unit
The perceptron model does the following steps.
The input is x. Its connection to the neuron has a weight which is w. Whenever a value flows through a connection, you multiply the value by the connection’s weight. For the input x, what reaches the neuron is w * x. A neural network “learns” by modifying its weights.
The b is a special kind of weight we call the bias. The bias doesn’t have any input data associated with it; instead, we put a 1 in the diagram so that the value that reaches the neuron is just b (since 1 * b = b). The bias enables the neuron to modify the output independently of its inputs.
But, data is not always linear!
We can show non-linear relationships in data using Activation functions. In simple words, in order to fit curves, we will need to use activation functions(mathematical functions). There are many activation functions available such as Relu, Selu, elu, tanh, etc. here is the list of activation functions to experiment with https://en.wikipedia.org/wiki/Activation_function
The below figure shows the modified version of the perceptron model. The model below includes activation functions that are used to show the non-linearity in data.
The steps that are carried out in the modified model are as follows
- Inputs (x1, x2..etc) along with random weights are fed to the neurons
- Each neuron performs a weighted summation of input, weights, and bias (constants)
- The final output goes to the activation function, the activation function outputs the final output.
In order to build a neural network, the layers of neurons have to be stacked one after the other. Which will eventually result in a multi-layer perceptron model (neural network).
The neural network consists of an input layer, hidden layers(one or more), and an output layer.
Every neuron in one layer is connected to every other layer of neurons, forming a dense neural network. The connections from layer to another layer is called synapse in the context of biological neural network. As mentioned above, every input layer, hidden layer, and output layer will have activation functions.
The commonly used activation functions in the input layer and hidden layer are Relu and tanh . However, in the output layer, the sigmoid activation function is used for binary classification and softmax for multiclass classification problems. But, for the regression analysis, the activation function changes for the output layer such as the Linear activation function.
A neural network requires resources, training data, ability, and time to construct. To create a neural network, most data mining platforms provide at least the neural network algorithm. In this article, we’re going to work through a classification problem with the Keras framework. In other words, taking a set of inputs and predicting what class those sets of inputs belong to.
The steps required to build a neural network are as follows:
ANN Implementation in Python
- 1. Data Preprocessing
- 1.1 Import the Libraries
- 1.2 Load the Dataset
- 1.3 Split Dataset into X and Y
- 1.4 Split the X and Y Dataset into the Training set and Test set
- 1.6 Perform Feature Scaling
- 2. Build Artificial Neural Network
- 2.1 Import the Keras libraries and packages
- 2.2 Initialize the Artificial Neural Network
- 3. Train the ANN
- 3.1 Fit the ANN to the Training set
- 4 Predict the Test Set Results
- 5. Make the Confusion Matrix
For implementation, we use the Pima Indians Diabetes Dataset. You can download the dataset from https://www.kaggle.com/uciml/pima-indians-diabetes-database. Artificial Neural networks can be used for both classification and regression. And here we are going to use ANN for classification.
The dataset has the following features
The datasets consist of several medical predictor variables and one target variable, Outcome. Predictor variables include the number of pregnancies the patient has had, their BMI, insulin level, age, and so on.
1.1 Import the Libraries
NumPy is a Python package that may be used to execute a variety of mathematical and scientific activities. NumPy is a Python library for working with arrays. It also provides functions for working with matrices, Fourier transforms, and linear algebra. Matplotlib is a plotting library that is used for creating a figure, plotting an area in a figure, plotting some lines in a plotting area, decorating the plot with labels, etc. Pandas is a tool used for data wrangling and analysis.
So in step 1, we imported all required libraries. Now the next step is-
1.2 Load the Dataset
So, when you load the dataset after running this line of code, the output is shown like this
As you can see in the dataset, there are 8 independent variables and 1 dependent variable.
1.3 Split Dataset into X and Y
We will also split the independent variables in X and a dependent variable in Y.
1.4 Split the X and Y Dataset into the Training set and Test set
We will use sklearn train_test_split class, to split the data into 80% percent train data and 20% test data
1.6 Perform Feature Scaling
Since the neural network performs well when the data is scaled. We will use a standard scaler object to standardize the independent variables
2. Build Artificial Neural Network
2.1 Import the Keras libraries and packages
Now, it is time to build a sequential model using Keras’s sequential class. Keras sequential is so simple, that you keep adding layers of neurons to build the neural network.
2.2 Initialize the Artificial Neural Network
We initialize the sequential object and start adding the input layer, hidden layer, and output layer. We use the add function to add all these layers one after the other. The input layer has 8 neurons as the first parameter, relu as the activation function as the second parameter and 8 input dimensions as the third parameter, this is because we have 8 independent variables in our dataset. The hidden layer has 10 neurons and relu as an activation function. The last layer i.e output layer has one neuron because we need to predict whether a person is diabetic or non-diabetic. The activation function used in the last layer is the sigmoid activation function.
Finally, we need to compile the model, the compile function includes an adam(Adaptive Moment Estimation) optimizer function to tune the weights of the model, the loss function is binary cross-entropy (normally used for binary classification problem) and the metric we want to monitor is accuracy. The aim is to reduce the loss and improve the accuracy of the neural network.
Note: this article will not discuss the different optimizers used in neural networks. However, optimizers are mathematical functions that are used to tune the weights of the neural network in order to improve the model’s predictive capabilities
3. Train the ANN
3.1 Fit the ANN to the Training set
Once the model is compiled, we need to train the neural network. The fit function in Keras does that job. The first parameter in the fit function is the 80% training part, the second parameter is the batch size, which specifies the number of training samples to be passed to the model for the training purpose. The last parameter is an epoch, epoch is the number of times you iterate through the entire training set in order to train the model. As you can see, as the number of epochs increases the accuracy of the model. However, care should be taken not to overfit the model by keeping a large number of epochs.
- Predict the Test Set Results
y_pred > 0.5 means if y-pred is in between 0 to 0.5, then this new y_pred will become 0(False). And if y_pred is larger than 0.5, then the new y_pred will become 1(True).
After running this code, you will get y_pred something like the above.
It is easy to explain how predictions are predicted correctly and how many are predicted incorrectly when we have a small dataset. But when we have a large dataset, it’s quite impossible. And that’s why we use a confusion matrix, to clear our confusion.
- Make the Confusion Matrix
In the above snapshot, the accuracy we obtained is 77%. That’s a pretty good one. However, you can always tune your model to improve the accuracy. Here is some common tuning we normally do to improve the model performance
Improving a model
Steps to improve your neural network model
- Creating a model– where you might want to add more layers, increase the number of hidden units (also called neurons) within each layer, and change the activation functions of each layer.
- Compiling a model– you might want to choose a different optimization function (such as the Adam optimizer, which is usually pretty good for many problems) or perhaps change the learning rate of the optimization function.
- Fitting a model– perhaps you could fit a model for more epochs (leave it training for longer).
There are many different ways to potentially improve a neural network. Some of the most common include: increasing the number of layers (making the network deeper), increasing the number of hidden units (making the network wider), and changing the learning rate. Because these values are all human-changeable, they’re referred to as hyperparameters) and the practice of trying to find the best hyperparameters is referred to as hyperparameter tuning.
In this article, we tried explaining neural networks and their implementation using the Keras framework. Hope you have understood.
import numpy as np
import matplotlib.pyplot as plt
import pandas as pd
dataset = pd.read_csv(‘/content/diabetes.csv’)
X = dataset.iloc[:,:-1]
y = dataset.iloc[:,-1]
from sklearn.model_selection import train_test_split
X_train,X_test,y_train,y_test = train_test_split(X,y,test_size = 0.2,random_state = 0)
from sklearn.preprocessing import StandardScaler
sc = StandardScaler()
X_train = sc.fit_transform(X_train)
X_test = sc.transform(X_test)
from keras.models import Sequential
from keras.layers import Dense
classifier = Sequential()
classifier.add(Dense(8,activation = “relu”, input_dim = 8,
classifier.add(Dense(10,activation = “relu” ))
classifier.add(Dense(1,activation = “sigmoid”))
classifier.compile(optimizer = ‘adam’ , loss = ‘binary_crossentropy’,
metrics = [‘accuracy’] )
classifier.fit(X_train,y_train,batch_size = 10,epochs= 100)
y_pred = classifier.predict(X_test)
y_pred = (y_pred > 0.5)
from sklearn.metrics import confusion_matrix, accuracy_score
cm = confusion_matrix(y_test, y_pred)
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text:
"Plundered My Soul" was a celebrated "Exile on Main Street" leftover released earlier this year, but some true classic Stones songs were longtime dust-gatherers as well. The 1981 "Tattoo You" album was almost entirely made up of reworked leftovers, including "Start Me Up" (a reggae song from the "Black and Blue" sessions remade for "Some Girls") and "Waiting on a Friend," the instrumental tracks of which dated back to the 1972 sessions for "Goats Head Soup." Here. Ron Wood (L) and Mick Jagger of the Rolling Stones perform on stage in Vienna's Ernst Happel Stadium. The show was part of the Rolling Stones' European "Forty Licks Tour."
Copyright © 2018, Hartford Courant

domain: entertainment


text:
We are excited to be working with one of UK's fastest growing PE backed Software businesses. The business is rapidly growing both organically and through a significant number of acquisitions.
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domain: finance


text:
Mental health is a important element of our total wellness. It is defined as a state of well-being in which an individual realizes their own capabilities, can handle the regular stresses of life, can function productively, and is able to add to their community. Mental health concerns are usually stigmatized as well as forgotten, leading to a considerable impact on the top quality of life for those affected. In this write-up, we will talk about the significance of recognizing mental health, looking for treatment, and also why we need to all care as a culture regarding mental health.
What is Mental Health?
Mental health is a state of emotional, emotional, as well as social wellness. It is just as essential as physical wellness as well as affects every aspect of our lives, including our partnerships, job, and also general quality of life. Mental health can be influenced by a range of factors such as genes, ecological variables, distressing experiences, and also way of life behaviors.
Mental health problems can show up in different methods, including anxiety, depression, state of mind problems, personality disorders, consuming conditions, and also addiction. These problems can have a considerable impact on an individual’s capacity to work and also can affect their personal and also expert life.
The Value of Recognizing Mental Health
Acknowledging mental health is the very first step towards taking care of our psychological wellness. It is important to acknowledge that mental health concerns are not a sign of weak point, yet rather a typical human experience. By recognizing mental health, we can reduce the preconception surrounding mental health problems and urge people to seek treatment.
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Getting Treatment for Mental Health Issues
Getting treatment for mental health concerns is important for boosting our general health and wellbeing. There are a selection of treatment options offered, consisting of treatment, medicine, and also way of life changes such as exercise as well as stress administration. It is very important to locate a treatment strategy that functions finest for the individual and also their details needs.
Looking for treatment for mental health issues is commonly stigmatized as well as misunderstood. This can bring about people avoiding looking for aid or not getting the needed assistance. It is very important to acknowledge the relevance of looking for aid for mental health problems and also to develop a supportive atmosphere that motivates people to seek therapy.
Why We Ought to All Appreciate Mental Health as a Society
Mental health concerns have a substantial influence on society as a whole. Mental health issues can impact an person’s capacity to function, go to school, as well as add to their neighborhood. Furthermore, unattended mental health issues can result in an enhanced danger of physical illness, chemical abuse, as well as self-destruction.
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domain: psychology


text: British singer/songwriter and vocal powerhouse, Emeli Sandé had a long four-year hiatius, but is back with a very powerful new single, Hurts. A record which is one of her most powerful and compellingly vulnerable to date, as she let’s out some really vulnerable soul vocals of a hurtful heartache relationship she went through. With the very amazing uptempo handclaps, strings and dramatic choir of the production really bringing the true hurt Sandé has felt of an underappreciated lover to life. Hurts is also the lead single to her upcoming long-awaited sophomore album, Long Live The Angels, which she announced is due out Nov. 11th and revealed the tracklisting for in a press release. In that same press release Sande had this to say about the record, “This entire album is about me not holding back and not censoring myself, and ‘Hurts’ is an explosion, it’s just…real talk.” While you wait for her new album, check her very absolutely enormous monster of a comeback record below.

domain: artistic


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Scottsdale (Ariz.) Desert Mountain coach Tony Tabor says the recruitment of 2014 wide receiver Mark Andrews has hit a new high. "He has really blown up," Tabor said. "I knew he was going to be good, but it's really taken off. I thought he would be...Blog | May 30, 2012

domain: sports


text:
The geopolitical zone used to be under the full control of the PDP, including most of the National Assembly seats but the February 25 election is the first since 1999 that the PDP didn't win more seats than any other party in the south-east.
In fact, the narrative has changed for those who believed that PDP's dominance in the south-east would continue for a longer time. The meteoric rise of the Labour Party (LP) propelled by the Peter Obi movement almost swept the PDP into political oblivion in the south-east in the just concluded national assembly elections.
According to the results published by the Independent National Electoral Commission (INEC), only seven members of the PDP got elected to the 10th national assembly – six in the house of representatives and one senator. In other words, the PDP has just seven lawmakers out of 58 national assembly seats in the south-east.
Meanwhile, in 2019, 41 lawmakers – 31 in the lower legislative chamber and 10 in the red chamber – were elected on PDP's platform in the zone, although some later defected to other political parties.
HAS LABOUR PARTY REPLACED PDP IN SOUTH-EAST?
In February, the PDP suffered a heavy blow in the south-east, not from the All Progressives Congress (APC) that began ruling at the centre in 2015, but from a political party which before now didn't harvest any significant victory during elections in the zone.
The LP got a total of 25 national assembly seats in the February 25 elections – 20 in the house of representatives and five in the senate.
The APC had 13 elected members – six senators and seven reps-elect.
Although INEC is scheduled to conduct a supplementary election to fill five seats, all indications show the PDP still may not be able to hold significant control of the south-east, even if it wins all.
BREAKDOWN OF THE ELECTED MEMBERS
In Abia, the PDP won only one house of representatives seat. The party did not secure any senate seat. LP picked six house of representatives seats, while APC got one.
In the upper legislative chamber, APC, LP and APGA got one seat each.
Okezie kpeazu, the PDP governor of the state who contested the Abia south senatorial district election, was defeated by Enyinnaya Abaribe of the All Progressives Grand Alliance (APGA).
LP won two house of representatives seats in Imo, while PDP and APC got three each. Two seats are yet to be filled as the electoral umpire will conduct a supplementary election in the two federal constituencies.

domain: news


text:
علامات کتنے دن بعد ظاھر ھونا شروع ھوتی ھیں؟
in this video we briefly talk about the facts that after how many days after the exposure to the virus a person on average can start feeling the symptoms of the disease.
these can be because of any other problem as well.
the main aim of making this video is only to make people aware about those issues which are concerning to their health.
as a doctor i believe in this present time helping people and guiding them properly is the only way forward.
stay home,stay safe and stay blessed.
COVID-19.کرونا وائرس آپ کے سوال اور ھمارے جواب
in this video i answer different questions on corona virus in urdu
شوگر کے مریضوں کے لئے۔۔اقسام۔۔علامات۔۔۔تشخیص۔۔۔علاج
Day by day change in symptoms of corona virus
In this video we will discuss the pattern of development of symptoms once a person has been exposed to the virus.
These are on average symptoms and these develop in those people who are symptomatic.
COVID-19:Story of Another Patient.Symptoms,Diagnosis and Treatment.
In this video i will narrate the story of another COVID-19 Patient.
I will explain how he developed symptoms,how he was diagnosed and how he was treated.
COVID-19:Why some people are affected more than others?4 most important things to remember::
In this video i will answer three most important questions asked by subscribers.
1=why some people get more sick than others?
2=what are 3 or 4 most important things we need to keep in mind during days we are sick with virus
3=what are issues during the recovery phase of COVID-19?
Answers to Two of your Most Asked Questions
In this video i will give answers to the 2 most asked questions from me on this channel.
In one i explain to the people to please avoid experimenting with medicines at home because these medications do have side effects which need to be monitored in hospitals.
Secondly i try to explain the safe approaches towards infants and babies in terms of dealing with infections.
COVID-19:How to avoid and Manage Stress and Depression during Isolation
In this video we will address a very important issue and that is how to save oneself going into stress,depression and anxiety while in isolation due to COVID-19 and if some one does develop these problems then how to get rid of these .
Always Remember stress will affect your immunity in a very negative way so its always important to avoid being depressed especially during these days.
So a healthy daily routine, eating healthy diet and staying positive will always be of great help.
What is the difference in symptoms of Common flu and corona virus
In this video we will discuss what are major and common differences between the symptoms of common flu and corona virus
کالا یرقان کیا ھے؟جانئے سب کچھ اس ایک وڈیو سے۔۔۔
in this video i talk about Hepatitis B virus infection in Urdu/hindi
کرونا کی علامات۔ سونگھنے کی صلاحیت کا چلا جانا۔ اور ہسپتال کا رخ کب کرنا ہے۔
For latest updates also watch the Corona Virus Update video.
سونگھنے کی اور ذائقہ کی صلاحیت کب ٹھیک ہوگی
چل نہ پانے سے اس ویڈیو میں مراد یہ ہے کہ اتنی نقاہت محسوس ہونا کہ انسان اپنے روزمرہ کے کام بالکل نہ کر سکے۔
بخار،گلے میں درد اور جسم میں درد کے لئے کیا لیں؟
Clinical Classification of COVID-19
In this video we will discuss about clinical classification of patient suffering from corona virus infection
کرونا وائرس کی علامات(corona symptoms in urdu(
Please also subsctibe my urdu channel.link is
ایک مریض کی کہانی مریض کی ذبانی،کب کیا ھوا اور علاج کیسے کیا؟
Answers To Your Most Frequently Asked Questions.
In this video i try to give Answers to the most frequently asked question by my youtube subscribers.
We will talk how to live a careful life in current situation and how to best protect the society from any harm.
کرونا میں مبتلا میرے مریض کا کیا بنا اور ھمارے کچھ لنڈے بازار کے ڈاکٹرز
What is diabetic neuropathy
How to check and improve your Breathing
In this video we will talk about three things.First two will be related with how to check your breath status while at home and third will be related how to improve your breathing in case the first two tests show that your breathing is compromised.
Firstly ,sit relaxed for 5 minutes and then inhale through your nose.after that exhale your nose by pinching it and also start stop watch.wait till you can comfortably hold your breath and then release pinch from your nose once you feel desire to take breath and note the seconds on watch.
Secondly,i explain the use of pulse oximeter in order to assess how well your respiratory system is functioning.
In the last and third part i explain a method using which we can improve our breathing.Take breath through nose ,pinch it close and exhale through your mouth making it purse lip and repeat it five times.you can do it 3 to 5 times a day.
how much bricks done by a mason per day || ایک مستری دن میں کتنی اینٹیں لگاتا ہے
in this video i will tell you how many bricks done bay a mason

domain: medical


text:
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Well laced is half won - Sparring gloves “Lace Up Pro” by Top Ten.
Although there are neither winners nor losers in sparring, you will quickly appreciate the benefits of boxing gloves with laces. More individualistic than lacing, you will not find a boxing glove that will fit your hands as well as Top Ten's “Lace Up Pro”. That you come with lacing high out, show the numerous hiking boots ladylike manufacturers. Here, too, one set in terms of security, stability, and individuality on a lacing. TOP TEN has skilfully incorporated and implemented this advantage in the “Lace Up Pro Series”.
Real leather and its qualities.
Genuine leather not only looks better, but it also feels better. Furthermore, it distinguishes the properties of breathability and flexibility. All boxing gloves from Top Ten are still sewn by hand and especially genuine leather convinces by its freedom from wrinkles. To enjoy your sparring gloves for a long time, you should have them aired well after use and remove any welding residue with a towel.
Sandwich construction and its advantages.
Top Ten uses padding in a sandwich construction in the “Lace Up Pro” series. As in the snack sandwich, a core layer is placed between two cover plates. This core layer has the task to distribute the forces occurring evenly and to protect the deck view. Not only in boxing gloves, this technique applies, also aircraft parts or railway cars benefit from the advantages of sandwich construction.
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domain: design


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