MXPA01006041A - Automotive trim with clear top coat and method of making same - Google Patents

Abstract

An exterior automotive trim product, and method of making the same. In certain embodiments, a color pigmented thermoplastic layer (75) is provided. A transparent clear coat (77) is calendared to the color pigmented layer (75) to form a composite or laminate. The laminate is subsequently vacuum-formed into a three dimensional shape approximating the desired shape of a final trim product. The vacuum-formed laminate (91) is then inserted into an injection molding device, and semi-molten resin (119) injected into the mold cavity behind the laminate (91). The resin fuses with the vacuum-formed laminate (91) with the result being the final automotive trim product. Thus, no spray painting or spraying of solvents is required, and burdensome dry paint transfer techniques may be avoided.

Description

COMPONENT OF AUTOMOTIVE FINISH WITH CLEAR FINAL COATING AND METHOD TO MANUFACTURE THE SAME FIELD OF THE INVENTION This invention relates to finishing components for automobiles and similar vehicles, as well as to methods for manufacturing same. More particularly this invention relates to exterior components of those vehicles, which are provided for purposes, either of appearance or have a size and shape that make a visual contribution to the exterior appearance of a vehicle.

BACKGROUND OF THE INVENTION It is known to apply automotive finishing parts to the exterior of wheeled vehicles, such as cars and trucks. Examples of such finishes include trim strips, fender elements for side doors, liners, wheel caps, grills and front fender strips. The present invention also applies to vehicle exterior components, which have been previously manufactured from plastic materials, such as door sides and the like. In the prior art, exterior, molded, automotive finishing components are typically painted in order to provide them with color. It is desirable that the color of the paint be compatible with the appearance of the vehicle (for example, that it be the same as that of the vehicle or complementary to it). Following the painting of a molded finish piece, a clear coating on the paint is often applied by spraying to give it shine. Before painting the molded finish part, it has often been necessary to prepare the exterior surfaces of these components by applying a primer (primer) that promotes the adhesion of the paint to the surface of the molded component. After the paint is applied to the primer, by spraying, the color appearance of the final product results from the pigmentation of the paint layer that is sandwiched between the clear coating sprayed on top and the underlying primer. Unfortunately, the application of spray painting of molded components, for use in vehicles, is often undesirable due to the potential of the resulting paint lines, the need for adhesive tape and the corresponding work involved. In addition, spray painting is undesirable due to the high cost of capital equipment, associated with the equipment of the paint application line, and potentially hazardous environmental problems, related to the required solvents and the like. In this way, it will be evident to those skilled in the art that it would be desirable to be able to manufacture automotive finishing components in a manner that would have a color compatible with automotive exteriors, without the need for paint application, by spraying, to the components molded. It is also known to manufacture plastic components for exteriors, automotive, simply as a product that is in the condition as it leaves the mold (ie without painting). For those components, the plastic that is used to mold the component by injection may include color pigmentation, so that the desired color appears not only on the surface, but in all molded articles. Unfortunately, the surface of these molded components, although initially having a desirable color, lacks brightness and can also be easily scratched and / or marred to further reduce their lack of brightness. For automotive, molded finishing components, there are numerous requirements or desired characteristics known to automobile manufacturers. It is desirable that these finishing components maintain their shape without becoming too soft in hot environmental conditions, or too brittle in cold weather. These products must also be capable of fixing and supporting exposure to the ultraviolet (UV) rays of the sun. It is also desired that certain components be able to possess a certain flexibility without permanently deforming or deforming. It is desirable that the surface appearance of these components exhibit a considerable gloss. Another approach to the application of color to these automotive finishes, includes the use of a dry paint film. A laminate applied as a dry paint coating can be used to replace the paint by conventional spraying. The dry laminate is produced by applying a coating of paint to a casting sheet, by conventional coating techniques. The dried paint coating is then transferred from the casting sheet to a finishing panel, by known dry paint transfer technology. The laminate can be subsequently thermoformed to produce a three dimensional shape and then integrally joined or molded to an underlying plastic car body member or panel. This known technology of dry paint film is described, for example, in US Pat. 5,725,712, the entire description of which is incorporated herein by reference. Figures 1-10 of the prior art will be referred to for the purpose of describing conventional dry paint film technology for application to automotive finishing components. Figure 1 illustrates a conventional automobile including numerous molded, plastic, exterior body components, which may be colored. The car 1 of Figure 1 includes the front fender strip 3, the wheel plugs 5, and many other exterior components that can be manufactured through injection molding technology. Patent 5,725,712 discloses a system for coloring automotive trim components. The first step in this dry paint film approach is the supply of the dry laminate 7 of Figure 2. The laminate 7 includes a self-supporting carrier sheet 9 (ie the cast film), the clear coating 11, the paint coating 13 and an optional sizing coating 15 to provide adhesion to a backing sheet in a subsequent rolling step. In order to manufacture the laminate 7, the clear coating 11 is coated on the carrier 9 by a complicated reverse roller coating process, shown in Figure 3 of the prior art, in which the clear coating lacquer is contained in the coating trough 17. The applicator roller 19 takes lacquer from the tundish and applies it to the carrier film 21 (or 9) after it passes over the guide roller 23. After leaving the nip (or of the matrix) between the applicator roller 19 and the rubber backing roller 25, the coated carrier film 27 passes into a multi-zone drying oven. The laminate is dried in the oven at temperatures from approximately 121.11"C to 204.44" C (250 * F to 400"F) through a multi-stage drying process, after drying a two-layer laminate is provided, which includes the carrier 9 and the clear coating 11. The color coating 13 is then attached to the clear coating 11 after the clear coating has dried on the carrier 9. The color paint coating 13 is typically applied to the carrier by techniques of reverse roll coating as shown in Figure 3, where the color coating is dried by passing it through multiple drying areas discussed above, in the curing of the clear coating.Thus, the complicated techniques of reverse rolling and the multi-zone drying ovens, of Figure 3, should be used on numerous occasions in order to apply the clear coating and the color coating to the The sizing coating 15 is subsequently applied to the paint coating 13, and is typically applied as a thermoplastic and dried in the same drying step in multiple steps, previously used for the clear and colored coatings. The result is the laminate 7 of Figure 2. The laminate 7 is subsequently laminated to produce a thermoformable backsheet, by means of dry paint transfer rolling techniques, shown in Figure 4, to form the laminate 29 of Figure 5. During this annoying rolling step of Figure 4, the paint coated laminate 7 is stored on a roller unrolled 31 and a flexible backing sheet of ABS 33 of 0.051 centimeters (20 mils) is stored on the unwind roll 35. When the rolls 31 and 35 are unwound as shown in Figure 4, and the continuous tapes pass respectively on the drums 37, the paint-coated laminate 7 and the ABS sheet 33 are joined to each other in the heated laminating drum 39 and the roller 41. The laminate 7 is attached to the tailored sheet 33 that the two pass between the rollers 39 and 41. The resulting laminate 29 then passes over the storage drum 43. The result is a roller of the laminate 29 of Figure 5, which includes a color determined by the color pigment that s e is found in the paint layer 13. The laminate 29 includes the backsheet 33, the sizing coat 15, the color coating 13 and the clear coating 11. Subsequently, the laminate 29 is thermoformed to produce the desired three-dimensional shape. Referring to Figure 6, the laminate 29 is placed within a holding frame 45 of a vacuum forming machine. The frame 45 moves towards the furnace 47 to heat the laminate 29. The backing sheet 33 is heated in the furnace 47 and the laminate 29 is buckled as shown at 49. Then, the fastening frame 45 is moved back to the position on the vacuum forming stand 51. The preheated laminate 29 is then vacuum formed to obtain a desired three-dimensional shape by creating a vacuum on the stand 51 through the connection 53 to a vacuum pump, and the stand 51 is raised to its position in Figure 7. The vacuum is drawn through the holes in the stand 51 to force the plastic from the preheated laminate 29 and produce the shape of the work surface of the stand 51. Subsequently, the three-dimensional, thermoformed laminate 29 is attached to a substrate panel as shown in Figures 8-9. The laminate 29 is placed inside an injection mold and fused to the face of an injection molded substrate 55. Figure 8 shows the preformed laminate 29 placed in the mold cavity, between the front and rear halves, 57 and 59, of the mold. The inner surface 61 of the mold half 57 coincides almost identically with the outer contour of the laminate 29 coated with paint. The surface 61 may be a rigid, highly polished, highly polished surface which is substantially free of surface defects, so that few or no defects are transferred to the high gloss surface with the clear coating applied of the laminate. After the laminate 29 is in place, the semi-molded injection molding material 55 is injected into the mold through the conduit 63 behind the preformed laminate 29. The molding material conforms to the shape of the mold cavity. mold and is permanently fused to the backing sheet 33 of the laminate 29 in the mold. A cross section of the resultant three-dimensional molded finishing component is shown in Figure 10. As can be seen above, dry paint film transfer technology is very problematic and complicated. For example, the process mentioned above, illustrated in Figures 1-10, requires passing through rolls and driers, on numerous occasions, as well as the period of time required to perform it. The process is very expensive due to the requirements and materials of the process. It has also been found that the life time of these finishing components can be limited because they lose their color quickly when exposed to heat, to the sun, to chemical products and the like. The requirements for all rollers, drums, laminates, dies and vacuum forming processes, and injection molding equipment, are very expensive. The cost of the tools is very high due to the requirement of vacuum forming tools, tools for injection, cutting tools, drums and rollers, and the like. In addition, the trimming of the materials after placement in the vacuum forming and injection cavities results in many wastes and lower yields. Problems have also been experienced with regard to the maintenance of the depth of the image (DOI), since the DOI can be lost due to pronounced stretching in the components. The depth of the bags or corners in the final molded components is also limited to the dry paint film, since it can not stretch more than necessary or will lose its color and / or gloss. U.S. Patent No. 5,037,680 incorporated herein by reference, discloses an exterior automotive component, with a pigmented substrate and a clear coating thereon. The substrate can be a thermoplastic polyolefin. Unfortunately, the clear coating material in the 5,037,680 patent is deposited on the substrate, in liquid form, for example by spraying, brushing, immersion, flow coating, etc. This application by spraying or wet application is undesirable for the reasons presented above (for example environmental consequences, the need for solvents, the expensive equipment required, etc.). From the foregoing, it is evident that there is a need in the art for automotive, color and molded finishing components, which: (i) can be manufactured without the requirement of transferring dry-colored paint film, of the art previous; (ii) they are colored to match or complement a color of the surrounding vehicle (iii) they can be manufactured at a lower cost than convenal dry paint film techniques, (iv) they have an adequate life time when exposed to the paint. heat, sun, chemicals, and the like; (v) can be manufactured without the requirement of the need to pass through chromed rollers and / or dryers on multiple occasions; (vi) they can be manufactured without excessive capital expenditure; (vii) can be manufactured without wasting large quantities of trimmed materials; (viii) maintain the DOI; (ix) are scratch resistant, have brightness, and are resistant to deterioration; (x) have great brightness and conservation of it; (xi) have uniformity of color; (xii) are resistant to gasoline and solvents, and to acid staining; (xiii) have a satisfactory hardness and abrasion resistance; (xiv) have a satisfactory impact resistance, (xv) have acceptable resistance to ultraviolet rays; (xvi) are resistant to exposure to water and moisture; and / or can be manufactured without the need for the application, by "spraying" or otherwise, of a clear coating in liquid form. There is a need in the art for molded finishing products, which have some or all of the features mentioned above, as well as methods for manufacturing the same. One purpose of this invention is to satisfy any and all of the needs described above in the art, as well as other needs that will be apparent to those skilled in the art, from the following detailed description of this invention.

SUMMARY OF THE INVENTION An object of this invention is to provide an automotive, exterior trim component, which is simple in construction, that is economical to manufacture and effective in operation. It is an object of this invention to provide an automotive, exterior trim component that is provided for exterior appearance purposes, which defines a color that matches or complements a surrounding color of a vehicle. Another object of this invention is to provide a molded, color pigmented substrate, on which a clear, substantially transparent coating is provided, or in a non-wet or non-liquid manner. The color substrate, in combination with the underlying clear coating, provides a finished, molded, composite component that has the durability, gloss and other appearance properties necessary for satisfactory automotive use outdoors. Another object of this invention is to eliminate the need for prior art dried color paint film transfer technology and to eliminate the need for spray painting of the automotive, molded finish components. Still another object of this invention is to place a thin layer of clear, laminated coating to a colored pigmented plastic substrate in an injection mold, and to inject additional plastic into the mold, in the semi-fused form, behind the clear / laminate coating of color, in order to manufacture an automotive, molded finishing component, which includes at least three layers. Yet another object of this invention is to vacuum-form, or thermoform, the clear coating compound and the color pigmented substrate, together in a single film, and then insert the vacuum formed laminate, into a cavity of a mold for injection and inject additional plastic material behind it, in order to produce an automotive, molded finishing component. Another object of this invention is to manufacture an automotive finishing component, solely by vacuum forming a composite laminate, a thin, thin coating, and a thicker, underlying, pigmented substrate. Another object of this invention is to place a clear coating layer, laminated to a carrier (e.g. polyester or the like) in the cavity of an injection molding apparatus, and then inject colored, semi-fused pigmented material into the cavity, behind of the laminate, such that the color pigmented material contacts and bonds with the clear coating and the final finishing product conforms to the shape of the cavity mold. The carrier can be detached from the clear coating before the product has cooled and removed from the injection molding apparatus. Still another object of this invention is to extrude a colored pigmented plastic substrate, vacuum forming the same to produce a film, then placing it in an injection mold, and injecting, behind it, additional plastic, colored or not, to cool it, resulting in an automotive, molded and colored finishing component. In other embodiments of this invention, an object of this invention is to simulate glass by providing all the layers of the resulting, substantially transparent product (s) and / or product (at least about 70% transparent) to visible light. In these modalities, the products can be used instead of glass windows in cars and other types of vehicles. Alternatively, still in other embodiments of this invention, methods of certain embodiments herein may be used to produce products that simulate stained glass, wherein all of the layers of those products are preferably at least about 20% transparent to visible light. This invention further satisfies the needs described above, in the art, by providing a method for manufacturing an automotive, colored finishing product, the method comprising the steps of: providing a clear, substantially transparent coating layer on a carrier layer, to form a clear coating laminate; calendering the clear coating laminate to a color substrate that includes the color pigment material therein, using at least one first and second rolls to form a color laminate including the clear coating, the carrier layer, and the color substrate, wherein the color substrate is opaque to visible light, - thermoforming the color laminate, to produce a desired three-dimensional shape, in a vacuum forming apparatus, to provide a color laminate, thermoforming; providing the thermoformed color laminate, in a cavity of an injection molding apparatus; injecting fluid resin into the cavity of the injection molding apparatus, behind the thermoformed color laminate, to provide a color finishing product having at least three layers; and removing the carrier from the finishing product. This invention satisfies the needs described above, in the art, by providing a method for manufacturing an automotive, colored finishing product, the method comprising the steps of: providing a clear, substantially transparent coating layer, (77), on a carrier layer (78) to form a clear coating laminate; thermoforming the clear coating laminate, to produce a desired three-dimensional shape; placing the clear coating laminate in a cavity of an injection molding apparatus; and injecting a colored, fluid material, into the cavity of the injection molding apparatus, behind the clear coating laminate, to form a three-dimensionally molded color product; remove the carrier from the clear coating; and using the color product, three-dimensionally molded, as a finishing product on a vehicle. This invention also satisfies the needs described above, in the art, by providing an automotive finishing product comprising: a colored pigmented layer, having a tensile strength of at least about 703.1 kg / cm2 (10,000 psi) and a thickness of at least approximately (0.127 cm) 0.050 inches; a clear, substantially transparent coating, at least about 90% transparent to visible light rays, the color pigmented layer and the clear coating, are included in a three-dimensional thermoformed laminate; and the thermoformed laminate can be used as an automotive finishing product, wherein the laminate has a gloss retention of at least about 95%.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view, of the prior art, of a car. Figure 2 is a cross-sectional, side view, of the prior art, of a carrier coated with paint, having a transparent coating thereon. Figure 3 is a side elevation, schematic view of the prior art, illustrating a step during the manufacturing process of the laminate of Figure 2. Figure 4 is a side view, schematic of the prior art, which illustrates a rolling step used in the manufacture of the laminate of Figure 5. Figure 5 is a cross-sectional view, of the prior art, illustrating a dry, composite paint coating transferred to a backing sheet during the lamination step (it is noted that the thicknesses of the film are exaggerated in the drawings herein and that they are not to scale, for purposes of simplicity). Figure 6 is a schematic view of the prior art illustrating a thermoforming step in which a paint-coated laminate of Figure 5 is heated prior to vacuum forming. Figure 7 is a schematic view of the prior art, illustrating the vacuum formed of the laminate of Figures 5-6. Figure 8 is a cross-sectional view, of the prior art, illustrating a preliminary step in which a laminate formed under vacuum is inserted into the cavity of an injection molding device. Figure 9 is a cross-sectional view, of the prior art, illustrating the injection of plasticized or semi-molded material into the injection molding device of Figure 8, behind the vacuum formed laminate, in order to form a component or product of automotive finishing, molding. Figure 10 is a cross-sectional view, of the prior art, of a section of the automotive finishing component, formed in Figure 9. Figure 11 is a cross-sectional view of a laminate for automotive finishing, molding, in accordance with with one embodiment of this invention. Figure 12 is a cross-sectional view of a vacuum-formed automotive finishing component, which is inserted into an injection molding device, in accordance with an embodiment of this invention. Figure 13 is a cross-sectional view illustrating the plasticized material that is injected into the molding cavity of Figure 12, behind the vacuum formed laminate, in order to manufacture a colored, molded, automotive finishing component; in accordance with one embodiment of this invention. Figure 14 is a cross-sectional view illustrating a substantially flat color laminate that is inserted into an injection molding device in accordance with one embodiment of this invention. Figure 15 is a cross-sectional view illustrating the plasticized material being injected into the molding device of Figure 14, to form a molded automotive finishing component in accordance with one embodiment of this invention. Figure 16 is a partial cross-sectional view of an automotive finishing component, in accordance with one embodiment of this invention. Figure 17 is a partial cross-sectional view of an automotive finishing component, in accordance with another embodiment of this invention. Figure 18 is a partial cross-sectional view of an automotive finishing component, in accordance with yet another embodiment of this invention. Figure 19 is a perspective view illustrating an injection molding device that can be used for the manufacture of automotive finishing components, in accordance with any of the different embodiments of this invention. Figure 20 is a perspective view illustrating a composite made from a transparent coating, thin, on a colored pigmented substrate, placed within the cavity, either of an injection molding device or of a vacuum forming device, in accordance with certain embodiments of this invention. Figure 21 is a perspective view of an injection molding device that can be used in the manufacture of automotive finishing components, in accordance with any of the different embodiments of this invention. Figure 22 is a cross-sectional view illustrating the placement of a colored pigmented substrate and a transparent, top-covering laminate product in a vacuum forming device in accordance with an embodiment of this invention. Figure 23 is a side cross-sectional view illustrating the vacuum formed of the laminate of Figure 22. Figure 24 is a side, cross-sectional view of the three-dimensionally molded laminate resulting from the process of Figures 22- 2. 3. Figure 25 is a side cross-sectional view illustrating the molded laminate of Figure 24, being placed in an injection molding device and subsequently injecting plastified or semi-molded material into the molding cavity behind the preformed laminate, in order to manufacture an automotive, molded finishing component, in accordance with one embodiment of this invention. Figure 26 is a schematic diagram illustrating a rolling apparatus, for joining together a transparent coating layer and a colored pigmented thermoplastic layer, in accordance with one embodiment of this invention. Figure 27 is a cross-sectional view of a portion of a laminate, including a transparent coating layer mounted on a carrier layer, in certain embodiments of this invention. The carrier is removed after the laminate has been thermoformed in an injection molding device or in a vacuum forming apparatus. The carrier can be removed manually by peeling.

DETAILED DESCRIPTION OF CERTAIN MODALITIES OF THIS INVENTION Referring now, more particularly, to the accompanying drawings, in which like reference numerals indicate like parts in all different views. It should be understood that the finishing products according to certain embodiments of this invention are adapted to be mounted to vehicles such as those illustrated in Figure 1 of the prior art, as well as in other types of automotive vehicles including sedans, vans ( "station wagons"), limos, trucks and similar. The present invention relates to the construction of finishing components, adapted for use on the outside of automotive vehicles. The components are to be provided for purposes of exterior appearance, such that either they match the color of the corresponding vehicle, or they complement the color of the corresponding vehicle. Exemplary automotive finishing products, which can be manufactured in accordance with the methods described herein, include wheel plugs, door sides, front fender strips, trunk covers, liners, body side moldings, roof moldings , emergency seat moldings, window moldings, grills, and the like. In other embodiments, entire panels for the automotive exterior body such as hoods, door panels, quarter panels, trunks, and the like, may be manufactured in accordance with the methods and products resulting from this invention. In certain different embodiments, the methods and products herein may be used as components in devices other than automobiles, such as snow vehicles, lawn tractors, and the like. For example, the methods and products herein can be used as awnings or other types of panels in vehicles such as tractors and snowmobiles. Figure 16 is a side cross-sectional view of an automotive finishing component 71 in accordance with an embodiment of this invention. The finishing component 71 includes a base substrate 73 preferably formed by injection molding or the like, a colored pigmented thermoplastic substrate 75 preferably formed by extrusion, and a transparent, upper, substantially transparent coating layer 77, preferably formed by extrusion . In accordance with certain embodiments of this invention, the color pigmented layer 75 and the clear, solid (ie, non-liquid) coating layer 77 can be calendered together to form the laminate 79 of Figure 11. The laminate 79 is it can then give, by vacuum forming, approximately the shape of the desired final finishing product. The laminate 79, formed under vacuum or thermoforming, can then be placed inside a cavity of an injection molding device, and plasticized or semi-molded resin material can be subsequently injected into the cavity, so as to form the base substrate 73 which it becomes attached or fused to layer 75 due to the heat and pressure present in the cavity. The cavity defines the three-dimensional shape of the final finishing product. Figure 16 illustrates a cross section of the final finishing product of this embodiment. In accordance with certain embodiments of this invention, the need to spray a paint layer and / or spray, or otherwise apply, a clear, liquid coating layer is eliminated. In this way, the resulting product can be manufactured more efficiently, with less capital expenditure, since a paint or spray line is not needed, and in a safer way from the environmental point of view, since it is not needed of solvents or other hazardous materials that are typically used in liquid application processes. Referring to Figures 16 and 11, the base substrate 73 may be made from any semi-molten resin, based on polymers, which is injected into the cavity of an injection molding device. The substrate 73 may be transparent or optionally it may be colored or opaque. The molded polymer substrate 73 may be selected to provide rigidity and other desired properties. Suitable polymers for making the base substrate 73 include, for example, polyvinyl chloride, polycarbonate, polystyrene, polypropylene, polyethylene, acrylonitrile-butadiene-styrene-nylon, copolymers, ionomers, polyolefin (TPO), copolymers of homopolymers and urethanes. Polyolefin, homopolymers and copolymers are thermoplastic resins that have good molding properties and can be used as the substrate 73 in preferred embodiments. Likewise, polypropylene has many behavioral properties suitable for automotive exterior uses, and like the acid polyethylene copolymers, all can be used as the substrate material 73. The substrate 73 can have a thickness from about 1.0 to 5.5 millimeters, most preferably from about 2.0 millimeters to 4.0 millimeters thick. The clear coating layer 77 is transparent or substantially transparent to visible light. In certain preferred embodiments, the clear coating 77 is at least 90% transparent to visible light rays, more preferably at least 95% transparent to visible light rays, and most preferably at least about 98% transparent to light rays. rays of visible light. The clear coating layer 77 is provided to give the finishing product a high gloss finish, to protect the color layer 75 and to provide a coating that is resistant to scratching, abrasion, usual wear, heat, UV radiation, and to the weather. . The clear coating 77 is also flexible and has satisfactory elongation characteristics during adhesion to the color pigmented layer 75. Different types of materials can be used to make the clear coating 77. The layer 77 can be manufactured, for example, from a resinous, synthetic, thermoplastic composition. The clear coating 77 may include, for example, or may be made of a mixture of a fluorinated, thermoplastic polymer, and an acrylic resin wherein the polymer component may be a thermoplastic fluorocarbon such as polyvinylidene fluoride and the acrylic resin may be a methacrylate. of polymethyl or polyethylene methacrylate resin, or mixtures thereof. Other materials that can be used to form clear coating 77, substantially transparent, include the polycarbonate base available from Avery Dennison (Troy, Michigan) or Kurz-Hastings (Philadelphia, PA). The clear layer 77 may have a thickness from about 0.000063 to 0.00762 cm (0.000025 to 0.003 inches), in certain embodiments of this invention. Additionally, in certain embodiments, the clear coating 77 may be placed on a polyester or polyethylene carrier, wherein the combination has a thickness of about 0.0013 to 0.008 centimeters (0.5 to 3 mils). The carrier (eg polyester or polyethylene carrier) remains with the clear coating 77 until such time as the clear coating is given the form of a formable film. The clear coating is calendered on the carrier, between hot rollers, using, for example, the apparatus shown in Figure 26. Figure 27 illustrates the clear coating 77 on the carrier 78, as a laminate. For example, the self-supporting carrier can be removed after the clear coating (and other layers laminated thereto) are thermoformed to the desired three-dimensional shape, and can be manually removed by peeling. This carrier can have a thickness from about 0.0025 to 0.006 centimeters (from 1.0 to 2.5 thousandths of an inch). The carrier functions to protect the clear coating during the manufacturing process and also supports the clear coating layer 77. Although the carrier 78 is removed after thermoforming, so that the final finishing products of the present do not include this carrier, the carrier 78 typically supports the clear coating layer 77 until after it has been thermoformed (eg, in a vacuum forming or molding apparatus by injection). Thus, when reference is made in this specification (not in the claims) to clear coating layer 77, and during the thermoforming thereof, it will be understood that the carrier 78 may be attached thereto for protection and support. The colored pigmented thermoplastic substrate 75 is the layer in the finishing product 71 that determines the color of the finish product. The substrate 75 is capable of being thermoformed. The color of the layer 75 is observed from the exterior of the vehicle, through the clear coating 77. The layer 75, in certain embodiments may comprise a thermoplastic, polyolefin resin (TPO), pigments that produce color and additives, ultraviolet stabilizers, and other additives conventionally used in thermoplastic resins to produce automotive exterior components. An exemplary material that can be used as a color pigmented layer 75 in certain embodiments of this invention is the Millenium IIIMR, which is a rigid polycarbonate sheet filled with glass, with optional layers of GE Lexan ™ on top and part lower (coextrusion in three multiple ABA). Millenium III is available from Spartech Alloy Plastics, and is a composite product of 20% (preferably from about 10 to about 30%) of glass-filled polycarbonate, which provides the physical properties of glass-filled polycarbonate, with a "Class" finish. A "of a standard polycarbonate sheet. Additional, exemplary color materials that can be used as layer 75 include the Montell Hivalloy polyolefins where copolymer alloys are created between the polyolefins (e.g. semicrystalline polymer) and usually incompatible amorphous polymers. This creates for layer 75. This creates for layer 75 a continuous polyolefin matrix with a dispersed amorphous phase, wherein the polymers chemically bond in a manner similar to a graft copolymer. The amorphous polymer components may be styrene or acrylic. This material for layer 75 has a low density from about 0.93 to 0.95 g / cc, excellent chemical resistance, excellent weather resistance (including resistance to ultraviolet rays), etc. Both glass reinforced resin XPA 018, 30%, Both Montell Hivalloy, and the general purpose resin, high flow XPA052 Hivalloy, can be used in different embodiments of this invention. The injection pressure of these materials, if used, is preferably less than about 1,054 kg / cm 2 (15,000 psi) in certain embodiments of this invention, and most preferably less than about (703.1 kg / cm 2) 10,000 psi. In certain embodiments of this invention, the color pigmented layer 75 has a tension modulus (ASTM D-638, incorporated herein by reference) from about 35,154 to 49,215 kg / cm 2 (from about 500,000 to 700,000 psi), and more preferably from about 38,669 to 42,184 kg / cm 2 (from about 550,000 to 600,000 psi). In certain embodiments, layer 75 has a specific gravity of from about 0.8 to 1.3, preferably from about 0.9 to 1.2. In certain embodiments of this invention, the colored pigmented layer 75 has a tensile strength (ASTM D-638, incorporated herein by reference) of at least about 703.1 kg / cm2 (10,000 psi), and preferably at least about 773.4 kg. / cm2 (11,000 psi). The layer 75 can have a tensile strength from about 773.4 to 844 kg / cm2 (from about 11,000 to 12,000 psi). In certain embodiments of this invention, the colored pigmented layer 75 has a flexural modulus (ASTM D-790, incorporated herein by reference) from about 49,215 to 56,246 kg / cm 2 (from about 700,000 to 800,000 psi), preferably from about 50,972.6 to 52,730.3 kg / cm2 (from approximately 725,000 to 750,000 psi). Also, in certain embodiments, layer 75 has a modulus of flex from about 1900 to 2000 MPa average. In certain embodiments of this invention, layer 75 has a flexural strength (ASTM D-790, incorporated herein by reference) of at least about 1,406.1 kg / cm2 (20,000 psi). Layer 75 preferably has a flexural strength from about 1,406.1 to 1,546.8 kg / cm2 (from about 20,000 to 22,000 psi). In certain embodiments of this invention, layer 75 has a coefficient of thermal expansion (ASTM D-696, incorporated herein by reference) from about 0.55 x 10"5 to 2.78 x 10 ~ 5 cm / cm / degrees C (from about 1.0 x 10"5 to 5.0 x 10" 5 inch / inch / degrees F), and more preferably from about 1.67 x 10"5 to 1.94 x 10" 5 cm / cm / degrees C (from about 3.0 x 10 ~ 5 up to 3.5 x 10"5 inch / inch / degrees F). Layer 75 preferably has a coefficient of thermal expansion of at least about 1.67 x 10"5 cm / cm / degrees C (3.0 x 10" 5 inch / inch / degrees F). In certain embodiments of this invention, layer 75 has a hardness (ASTM D-785, incorporated herein by reference) of al. less about 110 (Rockwell "R"), and more preferably at least about 115 (Rockwell "R"). In certain embodiments of this invention, layer 75 has a tensile strength at the point of permanent deformation from about 50 to 60 MPa average, a flexion temperature under load (455 kPa) from about 90 to 100 ° C average, and a bending temperature under load (1,820 kPa) from about 60 to 65 ° C. average The melting temperature of layer 75 is preferably from about 204.44 to 315.56 ° C (from about 400 to 600 degrees F), preferably from about 218.33 up to 260"C (from approximately 425 to 500 degrees F). Layer 75 also has less buckling than other materials such as the M910 ABS from Dow and the 811 ASA from Centrex. For example, in certain embodiments, when a 6.5 inch extension of the layer 75 is exposed to 121.11 ° C (250 degrees F) for one hour to measure the buckling of the layer, the suspended layer 75 is buckled down less than about 1.27 cm (0.5 inches), preferably less than about 0.76 cm (0.3 inches). In certain embodiments of this invention, the colored pigmented layer 75 may have (e.g., Hivalloy Acrylic / PP WPA011 from Montell, SAE J1960, exterior) a color shift (Delta E), black, less than about 0.5, preferably less than or equal to about 0.3, and most preferably less than or equal to about 0.2 (by example, material 1800 kJ / m2). The layer 75 can have a color change after 2500 kJ / m2 of less than about 0.3. Layer 75, alone, in certain embodiments of this invention, may have a gloss retention [eg, black color, initial 90.1, angle of 60 degrees, 2500 kJ / m2, to 84] of at least about 90% and preferably of at least about 93%. At another angle (e.g., observation at 20 degrees), layer 75, alone, in certain embodiments of this invention has a gloss retention [e.g., black color, initial 83.2, angle of 20 degrees, 2,500 kJ / m2, to 74.1] of at least about 80% and preferably at least about 89% at this 20 degree angle. Layer 75, alone, in certain embodiments, when subjected to the Florida SAE J1976 test, for 6 months (brightness at 60 degrees), has a gloss retention of at least about 90%, and preferably at least about 95.0% [? E = 0.12,? L = 0.05,? A = 0,? B = 0.09,? C = 0.08]. As for the white color, in certain embodiments of that invention, the layer 75 has a gloss retention of at least about 99% [? E = 1.8, acrylic SAE4 J1960 Montell Hivalloy / pp copolymer WXPA012]. With respect to chemical resistance, the color pigmented layer 75 preferably passes each of the following tests, for each of which the following chemicals were applied with a gauze swab and the exposure was for 48 hours. The tests were passed because after the application and exposure, the visual inspection showed no cracks or no cruciform cracks were observed. The tests that were passed were as follows: (a) at 23 degrees Celsius, plastic deformation level of 0%, the test was passed for each windshield washer fluid, automatic transmission fluid, tar cleaner and bituminous oil, liquid from brakes, coolant concentrate, engine oil, and C ASTM fuel + 15% MeOH applied separately to layer 75; (b) at 60 degrees Celsius, plastic deformation level of 0.0%, the test was passed for each of the chemicals in subsection (a) above except fuel; (c) at 23 degrees Celsius, plastic deformation level of 0.5%, the test was passed for each of the chemical products in subsection (a) above; (d) at 60 degrees Celsius, 0.5 * C, the test was passed for each of the chemicals in part (a) above except for the fuel; (e) at 23 degrees centigrade, plastic deformation level of 1.0%, the test was passed for each of the chemical products in subsection (a) above; and (f) at 60 'C, plastic deformation level of 1.0%, the test was passed for each of the chemicals in subsection (a) above except for the fuel. WXPA011 by Montell Hivalloy is an exemplary material for layer 75. Many conventional materials such as the Luran S ASA and Xenoy 1731 suffer from cruciform cracks or crack and do not pass many of the previous tests (especially the tar and bituminous oil remover, brake fluid, coolant concentrate, and scrubber fluid when effort is applied). The color imparted to layer 75 can be imparted by the ingredients and techniques known in the art. The color pigmentation of the resin layer 75 is carried out to produce a desired value in a color diagram. Typically, the coloration is provided to the resin substrate 75 using various combinations of color pigment additives such as titanium dioxide, blue tone green phthalocyanine, yellow tone green phthalocyanine, green tone blue phthalocyanine, carbon black and / or carbon black. The amounts of the color additives and the particular combinations thereof, used to achieve the desired color in layer 75, are known in the art. In layer 75 or layer 77, elements that prevent deterioration by ultraviolet radiation can also be provided. These include carbon black, white pigments, organic ultraviolet stabilizers, and other pigments that absorb and / or reflect ultraviolet radiation. Referring now to Figures 11-26, it will be described how the automotive finishing product 71 is manufactured in accordance with a first embodiment of this invention. To begin with, a color pigmented thermoplastic layer, extruded, 75, and a clear, substantially transparent, continuous tape or layer 77 are provided. These two layers 75 and 77 are then laminated or bonded together, for example by the apparatus shown in Figure 26. The continuous tape or clear coating layer 77 can be unrolled from the roll 81 while the color layer 75 is simultaneously unrolled from the roll. 83. After passing over the guide rollers 85, the color layer 75 and the clear coating layer 77 are located at the junction line between the hot, chrome plated rollers 87 and 89. The surfaces of the rollers 87 and 89 can be heated with oil to a temperature of approximately 104.44"C to 135" C (from approximately 220 * F to 275 'F). The pressure between rollers 87 and 89 can be from about 1.05 to 3.52 kg / cm2 (from about 15 to 50 pounds per square inch) in certain embodiments of this invention, more preferably from about 1.05 to 2.10 kg / cm2 (from about 15 at 30 pounds per square inch), and more preferably from about 1.05 to 1.41 kg / cm2 (from about 15 to 20 pounds per square inch). When the layers 75 and 77 pass between the rolls 87 and 89, this pressure and heat cause the two layers to join mechanically (to be laminated together). The resulting laminate 79 is removed from the rolls 87 and 89 and preferably stored on a roller. A cross section of the laminate 79 is shown in Figure 11. The laminate 79 can then be given a shape, by thermoforming, which approximates that of the desired final automotive finishing product by vacuum forming the laminate, both in the device of Figures 6-7 and in the vacuum forming device of Figures 22-23. If the vacuum forming device of Figures 6-7 is used, then the laminate 79 is placed in the fastening frame 45. The fastening frame 45 is then moved along a rail to the furnace 47 to heat the laminate 79 to a thermoforming temperature. The laminate 79 can be heated in the furnace 47 to a temperature of from about 121.11 ° C to 204.44 'C (from about 250"F to 400 'F) As the preheated laminate 79 (or 49) is buckled as shown in the' Figure 6, moves together with the clamping frame 45 back to its original position on the vacuum forming stand 51. The laminate 79 then receives, by vacuum forming, the desired three-dimensional approximate shape. A vacuum is created on the stand 51 through the connection 53 to a vacuum pump. The stand 51 is then moved to the clamping frame 45 and placed therein, where the vacuum is drawn through holes in the work surface of the stand 51 to force the molten plastic from the laminate 79 to take the shape of the easel work surface. Optionally, a positive air pressure can be applied to the free face of the laminate, on the opposite side of the ridge, in order to increase the forming pressure. It is noted that during the vacuum forming process, it is preferable that the color layer 75 be in contact with the working surface of the stand 51. The stand 51 remains in place long enough to cool the plastic laminate 79 again to a solid state before the frame stand 45 is removed. The result is a three-dimensional and thermoformed laminate 91, which is shown in Figure 12. The shape of the laminate 91 corresponds to the working surface of the stand 51. It is also It is possible to use the vacuum forming device of Figures 22-23 to shape a substantially flat laminate 79 of a three-dimensional laminate 91. Referring to Figures 22-24, the vacuum forming apparatus includes a molding or vacuum molding die 99, a plurality of vacuum suction holes 101 in the die 99 and a vacuum suction pump 103 communicating with the holes 101 through the duct to 105. An opening / closing valve 107 is provided such that the vacuum pump 103 can selectively exhaust air through the holes 101. The substantially flat laminate 79 is softened by heating to a preheat temperature as discussed above. . Following preheating, the stand or matrix 99 can be raised towards the laminate 79 and the gap 103 can be applied to remove the surface 75 from the color layer of the laminate 79 to make contact with the work surface of the matrix 99 as is shown in Figure 23. After it cools, the resultant vacuum formed laminate 91 is illustrated in Figure 24, with a three dimensional shape approximately that of the desired final automotive finishing component. Although the shape illustrated in Figure 24 is not identical to the shape of the vacuum formed laminate 91 of Figure 12, it is noted that the shape formed under vacuum depends on the stand or matrix of the vacuum forming apparatus, and that the shapes illustrated they are provided for example purposes only. Easels can be used, either males or females, in vacuum forming devices, in different modalities of this invention. The three-dimensional, vacuum-formed laminate 91 is then placed within the cavity 111 of an injection molding apparatus as shown in any of Figures 12 and 25. Figures 12 and 25 illustrate both cavities of different devices. of injection molding apparatus, wherein the cavities differ by at least the three-dimensional shape of the desired final product. The components of the injection molding devices of Figures 12 and 25 will be referred to using the same reference numerals for similar components of the device. Referring to Figures 12 and 25, the injection molding device includes first and second mold halves 113 and 115. The inner surface of the mold half or die 115 has a three-dimensional shape so as to roughly coincide with the shape of the outer surface of the clear coating layer 77 of the vacuum formed laminate 91. The laminate 91 is placed within the cavity 111 in such a manner that the clear coating layer 77 of laminate 91 rests on the working surface of the die 115. Semi-molded plastic resin 119 is then injected into the cavity 111 through • the opening 117 provided in the die 113 in order to form the molded base substrate 73. The pressure of the injection of the half-molded resin 119 into the cavity 111, combined with the temperature within the cavity and the surface of the die 115, causes the semi-molten resin 119 to melt with (or one with) the color pigmented thermoplastic layer, formed under vacuum, 75. The result is the three layer laminate 71 as shown in Figure 16, which is three-dimensionally molded for the desired automotive exterior application. This represents the final finishing product in this modality. In accordance with another embodiment of this invention, the finishing product 71 can be manufactured without vacuum forming. Referring to Figures 14-15, the thin and / or flexible, substantially flat laminate 79 can be placed within the cavity 111 of an injection molding device, without having previously vacuum-formed or pre-formed in some other way. . After the substantially flat laminate 79 is placed inside the cavity 111, the semi-molded plastic resin is injected into the cavity 111 through the opening 117. The pressure caused by the injection of resin 119 into the cavity 111, together with the temperature of the resin and the surface of the die 115 causes the laminate 79 to be pressed tightly against the working surface of the molding die 115, resulting in the layers 75 and 77 of the laminate 79 molded in the shape of the matrix 115 as shown in Figure 15. The resin 119 that forms the substrate 73 also has the shape of the mold. After being cooled, the result is the final automotive finishing product, a cross-section of which is illustrated in Figure 16. Figure 18 is a cross-sectional view of an end automotive finishing product, 121, in accordance with another embodiment of this invention. Finishing product 121 includes a clear coating layer 177 and a colored pigmented thermoplastic substrate layer 75. In this embodiment, a base substrate 73 is not provided or required. Finishing product 121 can be manufactured as follows. The flat laminate 79 can be manufactured as discussed above. The laminate 79 can then be formed in vacuum as discussed above. Followed by the vacuum formed, trimmed and cooled, the product is cut, molded, three-dimensional, final, 121, shown in Figure 18. Injection molding is not used. It is noted that in accordance with the embodiment of Figure 18 of this invention, the colored pigmented substrate layer 75 may be relatively thicker than the same color layer 75 in the embodiment of Figure 16. For example, the pigmented substrate 75 of the finish product 121 may have a thickness of at least about 0.152 cm (0.060 inches). Figure 17 illustrates a cross-sectional view of a portion of an end automotive finishing product, 123 in accordance with still another embodiment of this invention. The finishing product of this embodiment includes a base substrate 73 and a color pigmented thermoplastic substrate layer 75, but not a clear coating layer. The finishing product 123 can be manufactured in certain embodiments of this invention by vacuum forming the color layer 75 (without a clear coating layer thereon), as described above, to form a film. The vacuum formed three-dimensional film, consisting of the layer 75, is then placed in a cavity 111 of an injection mold as described above, and then semi-molded plastic material is injected into the mold cavity behind the film, in order to of forming the substrate 73. In this way, the finished product 123 can be manufactured without the need of the lamination assembly illustrated in Figure 26. In accordance with yet another embodiment of this invention, a clear coating layer 77 can be laminated to a layer of glossy metallic paper (for example, aluminum or chrome) (i.e. layer 75 can be this metallic paper type layer). This compound can be subsequently formed under vacuum as discussed above, then placed into the cavity 111 of an injection molding device. Later, the semi-molten resin can be injected into the cavity 111 behind the laminate and allowed to cure, so that the resulting three-layer product has the appearance of a part finished with chromium plate. In those embodiments, the metal foil layer can have a thickness from about 0.005 to 0.008 inches (for example chrome paper or glossy foil), and the clear coat layer 77 can have a thickness from about 0.000063 to 0.0076 cm ( 0.000025 up to 0.003 inches). This mode is advantageous because conventional chrome is easily scratched and easily altered with the weather. The metallic paper layer may or may not be provided on a carrier layer in different embodiments of this invention. In another embodiment of this invention, a single clear coating layer 77 can be formed under vacuum to obtain a film. That layer can have a thickness from about 0.008 to 0.018 centimeters (from about 3 to 7 thousandths of an inch). After vacuum forming, the molded clear layer is placed within the cavity 111 of an injection molding device and the color pigmented, semi-molten resin is injected into the cavity behind it to a thickness of from about 1.5 to 5 millimeters to result in the final two-coat finish product. Figure 19 illustrates, in general, an injection molding device 125 that can be used in any of the embodiments of this invention, mentioned above. Referring to Figure 19, the injection molding apparatus 125 includes a stationary plate 127, a movable plate 129, a mold unit 131 that includes dies 115 and 117 located between the plates 120 and 129. A connected injection mechanism 132 to the plate 127, and a fastening device 133 of the mold, attached to a moving plate 129. The injection mechanism 132 includes a heating cylinder, a screw, a plasticizing space defined between the heating cylinder and the screw, a nozzle, a hopper, a piston, and a sleeve, which are illustrated and described in greater detail, in any of the US Patent Nos. 5,562,931 or 5,486,327, the descriptions of which are incorporated herein by reference. The injection device 132 causes the semi-molten resin material to be injected into the cavity 111 as described above through an opening 117 defined in one of the mold halves. Figure 21 illustrates another injection molding device 135 which is similar to device 125 of Figure 19. In accordance with the different embodiments of this invention, any of the injection molding devices, vertical or horizontal, can be used. The injection molding device of the Figure 25 which can also be used in any of the embodiments of this invention, can function both as an injection molding device including the cavity 111 as well as a vacuum forming device that includes the vacuum 103, the valve 107, the conduit 105 and a matrix 99 (or 115). In this manner, vacuum forming and injection molding can be done in separate devices as described above, or it can be carried out, alternatively, in a single device as illustrated in Figure 25.

The final, automotive finishing products, 71 and 121, described above, are scratch resistant, have good durability, high gloss, hardness of good strength and satisfactory ultraviolet stabilization. These properties are described in relation to the surface of the products observed from the outside of a vehicle (ie the side of the products that have the clear coating). The degree of these physical characteristics with respect to brightness, DOI, color uniformity, gasoline resistance, ease of cleaning, resistance to acid stains, hardness, abrasion resistance, impact resistance, resistance to ultraviolet rays and resistance to water / moisture, are described later. These finishing products, with respect to gloss, preferably have a specular reflectance for the clear coating surface, of at least about 60-65 gloss units, at an angle of 20 'with respect to the perpendicular, and of at least about 75-80 units of brightness with an angle of 60 'with respect to the perpendicular. The specular reflectance and other criteria of this part are measured before polishing and waxing, and a preferred test method is described in test specification GM TM-204-A. The distinction of the image (DOI) is a measurement of the clarity of an image reflected by the finished surface. Each of these products has a DOI of at least about 60 units, where 100 is the maximum reading of the DOI, as measured by a Dorigon brightness meter model No. D47R-6F from Hunter Lab. Details of this test procedure The distinction of the image is described in the test specification GM-204-M which is incorporated herein by reference. With respect to gasoline resistance, each of these products undergoes substantially no change in color, degradation, tackiness, surface scratches, or the like, after submerging for 10 seconds, ten (10) times in gasoline, with a period of of drying of 20 seconds between each dive. Immediately after the tenth immersion, the surface of these products preferably passes the hardness test with the toenail, in accordance with the test specification GM TM-55-6 which is incorporated herein by reference. With respect to ease of cleaning, each of the aforementioned products can preferably support ten rubs with gauze saturated with naphtha 9981062 (or some product commonly used in other approved cleaning solvents), without substantial evidence of staining, discoloration or softening of the outer surface. This test does not require evidence of color transfer from the test part to the fabric. A rub consists of a forward and backward movement. With respect to resistance to acid staining, each of the aforementioned finishing products preferably supports exposure to 0.1 N sulfuric acid for sixteen (16) hours, without any evidence of staining, discoloration, or softening of the painted surface . As with hardness, each of the aforementioned finishing products has a hardness of at least four, based on the Knoop hardness test, which is incorporated herein by reference. As for the abrasion resistance, each of the finishing parts mentioned above, can preferably support the standard Gravelometer test identified in SAE J-400 at -23 'C (-10 * F), with a minimum rating of 8, and this test method it is incorporated herein by reference. As with the impact strength, each of the above-mentioned finishing products can preferably support at least 1.41 kg / cm2 (20 pounds per square inch) of direct impact, without fracture. As with ultraviolet light resistance, also known as accelerated exposure to weathering or QUV, each of the aforementioned products preferably does not exhibit any significant surface deterioration or embrittlement, adhesion loss, objectionable shrinkage, or color change. or notorious brightness, after approximately 500 to 1000 hours of exposure to ultraviolet light and to a condensation apparatus according to ASTM G-53 using an ultraviolet light cycle of eight hours at 70"C and a humidity cycle of four hours at 50" C, wherein this test procedure is incorporated herein by reference. As with exposure to water and moisture, each of the above-mentioned finishing products can withstand preferably ninety-six hours of exposure to moisture, at a relative humidity of 100% and at 37.77"C (100 * F). In a moisture cabinet defined in GM TM553 test specification (hereby incorporated by reference), and a water immersion test for two hours at 37.77"C (100 'F), in accordance with the specification of GM TM55-12 test (incorporated herein by reference). The resulting product preferably shows no evidence of blistering when examined one minute after removal from the test cabinet. Additionally, each of the final finishing products, mentioned above, can preferably support fifteen cycles of the humidity and cold cycle test defined in the test specification GM TM45-61A (incorporated herein by reference), without experiencing signs visible formation of cracks or formation of blisters. In alternative embodiments, the methods herein may be used to produce products that simulate glass windows (eg windshields, side windows, sunroofs, etc.) and the like. Any of the aforementioned embodiments can be used for this purpose, where all the layers (e.g., 73, 75, 77) of the product are substantially transparent to visible light (e.g., at least about 40%, and preferably at least about 70). % transparent to visible light) when it is desirable to simulate clear windows. When you want to simulate stained windows, all layers (73, 75, 77) are at least about 10% (preferably at least about 20%, and most preferably about 25%) transparent to visible light rays. In certain glass simulation embodiments of this invention, the clear coating layer 77 can be extruded together with the layer 75. These two layers can then be formed together under vacuum to produce a three-dimensional shape or profile that can be used as a windshield, window, or sunroof of a car, or instead of glass in any other appropriate application. Clear polycarbonate substrates may be used in certain of these glass simulant embodiments of this invention, such as layer 75 and / or 73. Once given the foregoing description, many other features, modifications and improvements will be apparent to the experienced person. in the technique. Those other features, modifications and improvements are therefore considered a part of this invention, the scope of which will be determined by the following claims.

Claims (19)

1. A method for manufacturing a colored automotive finishing product, the method is characterized in that it comprises the steps of: providing a clear, substantially transparent coating layer on a carrier layer, to form a clear coating laminate; calendering the laminate of the clear coating to a color substrate that includes therein a color pigment material, using at least one first and second rolls, to form a color laminate including the clear coating, the carrier layer, and the color substrate, the color substrate is opaque to visible light; thermoforming the color laminate to produce a desired three-dimensional shape in a vacuum forming apparatus, to produce a color laminate, thermoforming; providing the color laminate, thermoforming, in a cavity of an injection molding apparatus; injecting fluid resin into the cavity of the injection molding apparatus, behind the thermoformed color laminate, to provide a color finishing product, having at least three layers; and, remove the carrier from the finished product.

2. The method according to claim 1, characterized in that said first supply step includes providing the clear coating layer, substantially transparent, with a thickness in certain areas thereof, from about 0.000063 to 0.0076 cm (0.000025 up to 0.003 inches).

The method according to claim 2, characterized in that the clear coating layer is at least about 90% transparent to visible light rays.

4. The method according to claim 1, characterized in that the transparent coating laminate has a thickness from about 0.0013 to 0.008 centimeters (from 0.5 to 3 thousandths of an inch).

5. The method according to claim 1, characterized in that the carrier includes one of polyester and polyethylene.

The method according to claim 1, characterized in that the injection step includes injecting the fluid resin into the cavity, which has an interior of three-dimensional shape, so that the resulting color finishing product is molded with one way between: an automotive body side molding, an automotive roof molding, an automotive window molding, an automotive front grille, an automotive front fender, and an automotive wheel cover.

7. The method according to claim 1, characterized in that the fluid resin, injected in the injection step, is molded to a thickness of about 1.0 to 5.5 millimeters in areas thereof.

The method according to claim 1, characterized in that the color of the color substrate determines the color of the automotive finishing product, and in that the color substrate includes a polycarbonate filled with glass.

The method according to claim 1, characterized in that the color substrate includes a copolymer alloy which includes at least one polyolefin and an amorphous polymer.

The method according to claim 1, characterized in that the color substrate has a tension modulus conforming to ASTM D-638 from about 35,154 to 49,215 kg / cm 2 (from about 500,000 to 700,000 psi), a relative density from about 0.8 to 1.3, and a tensile strength, in accordance with ASTM D-638 of at least about 703.1 kg / cm2 (10,000 psi), a flexural strength in accordance with ASTM D-790 of at least about 1,406.1 kg / cm2 (20,000 psi), and a hardness, according to ASTM D-785 of at least about 110 Rockwell R.

11. The method according to claim 1, characterized in that the finish product has a gloss retention of at least approximately 95%.

12. A method for manufacturing an automotive, colored finish product, the method is characterized in that it comprises the steps of: providing a clear, substantially transparent coating layer with a thickness from about 0.000063 to 0.0076 cm (0.000025 to 0.003 inches); thermoforming the clear coating layer to produce a desired three-dimensional shape; placing the clear coating layer inside a cavity of an injection molding apparatus; e, injecting a colored material, fluid, into the cavity of the injection molding apparatus, behind the clear coating layer, to form a color, three-dimensional, molded product; and, use the color product, molded, three-dimensional, as a finishing product in a vehicle.

The method according to claim 12, characterized in that the described steps are carried out in the order in which they were described. 1 .

The method according to claim 12, characterized in that the step of thermoforming is carried out in the injection molding apparatus.

15. The method according to claim 12, characterized in that the step of thermoforming is carried out in a thermoforming apparatus that is separate and independent of the injection molding device.

16. A method for manufacturing an automotive product, the method is characterized in that it comprises the steps of: providing a clear, substantially transparent coating layer with a thickness from about 0.000063 to 0.0076 cm (0.000025 to 0.003 inches); thermoforming at least the clear coating layer to produce a desired three-dimensional shape; e, injecting a fluid material into a cavity behind the clear coating layer, to form a three-dimensional molded automotive product.

The method according to claim 16, characterized in that the thermoforming step includes vacuum forming the clear coating layer, and in that the fluid material is pigmented in color.

18. An automotive finishing product, characterized in that it comprises: a colored pigmented layer having a tensile strength of at least about 703.1 kg / cm2 (10,000 psi) and a thickness of at least about 0.127 cm (0.050 inch); a clear coating, substantially transparent, at least about 90% transparent to the rays of visible light, the color pigmented layer and the clear coating are included in a thermoformed and three-dimensional laminate; and, the thermoformed laminate can be used as an automotive finishing product, wherein the laminate has a gloss retention of at least about 95%.

19. The finishing product according to claim 18, characterized in that the colored pigmented layer and the clear coating are in direct contact with each other, and the finishing product further includes a base layer having a thickness of about 1.0. up to 5.5 millimeters, where the clear coating has a thickness from about 0.000063 to 0.0076 cm (0.000025 to 0.003 inches), and because the pigmented color layer is located between the base layer and the clear coating.