[go: up one dir, main page]

USRE35739E - Decorative sheet material simulating the appearance of a base coat/clear coat paint finish - Google Patents

Decorative sheet material simulating the appearance of a base coat/clear coat paint finish Download PDF

Info

Publication number
USRE35739E
USRE35739E US08/317,758 US31775894A USRE35739E US RE35739 E USRE35739 E US RE35739E US 31775894 A US31775894 A US 31775894A US RE35739 E USRE35739 E US RE35739E
Authority
US
United States
Prior art keywords
sheet material
film
pigmented coating
appearance
clear
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US08/317,758
Inventor
Thomas M. Ellison
Robert A. Winton
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Soliant LLC
Original Assignee
Rexam Industries Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=25450040&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=USRE35739(E) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Rexam Industries Corp filed Critical Rexam Industries Corp
Priority to US08/317,758 priority Critical patent/USRE35739E/en
Assigned to REXAM INDUSTRIES CORP. reassignment REXAM INDUSTRIES CORP. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: REXHAM INDUSTRIES CORP.
Application granted granted Critical
Publication of USRE35739E publication Critical patent/USRE35739E/en
Assigned to REXAM IMAGE PRODUCTS INC. reassignment REXAM IMAGE PRODUCTS INC. MERGER (SEE DOCUMENT FOR DETAILS). Assignors: REXAM INDUSTRIES CORP.
Assigned to REXAM DELAWARE CORPORATION reassignment REXAM DELAWARE CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: REXAM IMAGE PRODUCTS, INC.
Assigned to SOLIANT LLC reassignment SOLIANT LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: REXAM DELAWARE CORPORATION
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/78—Moulding material on one side only of the preformed part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/043—Superstructures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1657—Making multilayered or multicoloured articles using means for adhering or bonding the layers or parts to each other
    • B29C2045/166—Roughened surface bonds
    • B29C2045/1662—Roughened surface bonds plasma roughened surface bonds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2715/00—Condition, form or state of preformed parts, e.g. inserts
    • B29K2715/006—Glues or adhesives, e.g. hot melts or thermofusible adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/002—Coloured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0022—Bright, glossy or shiny surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0026—Transparent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0072—Roughness, e.g. anti-slip
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/722—Decorative or ornamental articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/14—Layer or component removable to expose adhesive
    • Y10T428/1424—Halogen containing compound
    • Y10T428/1429—Fluorine
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/16—Two dimensionally sectional layer
    • Y10T428/162—Transparent or translucent layer or section
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24893—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material
    • Y10T428/24909—Free metal or mineral containing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer

Definitions

  • the present invention relates to sheet materials generally, and particularly relates to a sheet material which can be used to provide a decorative surface on automobile body panels and the like.
  • Base coat/clear coat finishes pose significant (and expensive) pollution problems arising from the evaporation of harmful paint solvents. Moreover, they are difficult to provide on plastic automobile body panels, which are becoming a popular mode of construction in the industry. Finally, base coat/clear coat paint finishes in general involve multiple painting steps which are very expensive to perform when high quality standards are maintained.
  • objects of the present invention are to provide a way to produce automobiles and the like with high quality decorative finishes like a base coat/clear coat finish, which can be used on molded plastic body panels, which does not require expensive painting steps, and which serves to reduce the emission control problems previously faced by manufacturers who wished to produce automobiles with base coat/clear coat finishes.
  • a flexible decorative sheet material for use in surfacing automobile body panels and the like.
  • This sheet material is characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof.
  • the sheet material comprises a substantially transparent outer layer and a pigmented coating on the undersurface of the outer layer and visible therethrough.
  • the pigmented coating optionally has reflective flakes uniformly distributed therein to impart to the sheet material the appearance of a metallic base coat/clear coat paint finish.
  • the reflective flakes in the pigmented coating are preferably oriented generally parallel to the outer layer.
  • the outer layer is also preferably formed from a substantially clear film.
  • the pigmented coating is preferably of a thickness less than that of the substantially clear film. The precise thickness of the pigmented coating is, however, selected to impart the specific predetermined appearance to the sheet material which is desired.
  • Sheet materials of the present invention include dual-color sheet materials which comprise a substantially transparent outer layer and a pigmented coating on the undersurface thereof, wherein the pigmented coating comprises a first pigmented coating on certain portions of the undersurface of the outer layer and visible therethrough, and a second pigmented coating of a different color on certain other portions of the undersurface of the outer layer, which second pigmented coating is also visible therethrough.
  • the articles comprise a supporting substrate and a decorative sheet material adhered to one side of the substrate, conforming to the contoured surface, to impart to the outer surface the appearance of a base coat/clear coat paint finish.
  • the decorative sheet material is as described above.
  • the supporting substrate which may be formed of a number of materials, is preferably a rigid metal substrate or a molded polymer substrate.
  • Also disclosed herein is a method for making a decorative sheet material of the type described above.
  • This method comprises applying to one surface of a substantially clear polymer film, a thin coating of a pigmented polymer.
  • the pigmented polymer preferably has reflective flakes uniformly distributed therein.
  • the method is also described as comprising the steps of forming a substantially clear polymer film on a carrier, coating the film with a pigmented polymer optionally having reflective flakes uniformly distributed therein, and removing the coated film from the carrier.
  • the polymer film is preferably formed by reverse roll coating a solution of the polymer onto the carrier.
  • the step of applying a thin coating of a pigmented polymer to the film preferably comprises spraying a pigmented polymer which optionally has reflective flakes suspended therein onto the film, and drying the solution to form a thin, pigmented coating.
  • the pigmented polymer is preferably sprayed on the substantially clear film before the film has solidified.
  • the present invention allows paint and finish handling steps involving solvents to be performed in a central plant, and the "finish" to be shipped, in sheet form, to a number of automobile assembly plants and the like. This sensibly allows solvent emission control problems attendant to such procedures to be handled in a centralized location, reduces the emission control expenses at numerous assembly plants, and serves to reduce the cost and complexity of solvent emissions control in general.
  • FIG. 1 is a cross-sectional view of a decorative sheet material of the present invention.
  • FIG. 2 is a schematic diagram which illustrates the properties of sheet materials of the present invention.
  • FIG. 3 is a schematic illustration of a method for making decorative sheet materials of the present invention.
  • FIG. 4 is an article of the present invention with a portion broken away to show the decorative sheet material on the outer surface thereof.
  • a decorative sheet material 10 of the present invention is illustrated in FIG. 1.
  • the sheet material comprises a substantially clear film 11, a pigmented coating 12 on the undersurface of the preformed film, and an adhesive layer 13 carried by the inner surface of the pigmented coating.
  • the pigmented coating has reflective flakes 14 uniformly distributed therein.
  • the pigmented coating is opaque and uninterrupted; the reflective flakes are aluminum flakes or mica flakes.
  • Mica flakes used in the present invention may be untreated, or tinted or otherwise surface treated, as known in the art.
  • the reflective flakes are oriented generally parallel to the preformed film, with the flakes preferably being oriented so the mean angle of inclination of the flakes to the preformed film is less than about 6.5 degrees. The precise limits of the angle of inclination depends on a number of conditions, including the particular type of reflective flake used, the composition of the pigmented coating, and the composition of the preformed film.
  • the flakes contribute to the "flop" effect described previously. Flop is due to the orientation of the reflective flakes generally parallel to the surface of the finish. As illustrated in FIG. 2, the observer at A' sees the light A reflected by the flakes. A similar situation exists for the observer at B' with light B. Because of the phenomenon of flop, light intensity is lower at B' than A'; i.e., the finish appears darker at B' than A'.
  • Films 11 for practicing the present invention should be selected so they are pigmentable, thermoformable and weatherable.
  • the film 11 is about 0.5 to about 300 thousandths of an inch thick, and is preferably from about one to about two thousandths of an inch thick.
  • Such films are preferably substantially molecularly unoriented cast films, as opposed to films which have been oriented or biaxially oriented, and are preferably substantially colorless.
  • the cast film is formed before the pigmented coating is applied thereto.
  • Such films are prepared by a number of known liquid casting methods, such as by spreading a solvent solution having a polymer dissolved therein onto a carrier with a casting die, doctor bar, or reverse roll coater, then evaporating the solvent, and then stripping the polymer film from the carrier.
  • the reverse-roll coating method is the preferred method of making liquid cast films for the present invention.
  • Other liquid casting methods are also known and useful for practicing the present invention.
  • a plastisol, organosol, or dispersion of the polymer can be cast onto the carrier instead of a solvent solution.
  • polytetrafluoroethylene which is virtually insoluble, can be liquified and cast as a dispersion.
  • Such liquid cast film processes, and some current uses of cast films, are discussed in Plastics Engineering, at pages 29-33 (May, 1983).
  • substantially molecularly unoriented cast films are liquid cast films, and not melt cast films or films formed by extrusion.
  • Polymers suitable for forming such cast films are preferably weatherable polymers selected to provide a pigmented film which will not significantly fade, peel, crack, or chalk when exposed to the environment, for the intended life of the product for which the decorative sheet material is made.
  • weatherable polymers include fluoropolymers, acrylate polymers, urethane polymers, vinyl polymers, and blends thereof.
  • Acrylate polymers useful for practicing the present invention are obtained from a variety of acrylic monomers, such as acrylic and methacrylic acids, and their amides, esters, salts, and corresponding nitriles.
  • Particularly suitable monomers for such polymers are methyl methacrylate, ethyl acrylate, and acrylonitrile.
  • the polymers may each be used in the form of homopolymers, or with various other monomers which can be copolymerized therewith.
  • acrylate polymers useful for the present invention are polyacrylates and polymethacrylates which are homopolymers and copolymers of acrylic acid ester and methacrylic acid ester, such as, for example, polyacrylic acid isobutyl ester, polymethacrylic acid methyl ester, polymethacrylic acid ethylhexyl ester, polyacrylic acid ethyl ester; copolymers of various acrylic acid esters and/or methacrylic acid esters, such as, for example, methacrylic acid methyl ester/acrylic acid cyclohexyl ester copolymers; and copolymers of acrylic acid esters and/or methacrylic acid esters with styrene and/or alphamethylstyrene, as well as the graft polymers and copolymers and polymer mixtures composed of acrylic esters, methacrylic acid esters, styrene and butadiene.
  • Fluoropolymers useful for practicing the present invention include polymers and copolymers formed from trifluoroethylene, tetrafluoroethylene, hexafluoropropylene, monochlorotrifluoroethylene and dichlorodifluoroethylene. Copolymers of these monomers formed from fluoroolefins such as vinylidene fluoride are also useful. Further illustrative examples of fluoropolymers useful for practicing the present invention include polyvinyl fluoride and polyvinylidene fluoride.
  • the fluoropolymer may be a fluorinated ethylene/propylene copolymer (the easily-fabricated "FEP” resins), or a copolymer of ethylene/chlorotrifluoroethylene such as "HALAR.”
  • FEP fluorinated ethylene/propylene copolymer
  • HALAR ethylene/chlorotrifluoroethylene
  • Vinylidene fluoride/hexafluoropropene and vinylidene fluoride/perfluoro (alkyl vinyl ether) dipolymers and terpolymers with tetrafluoroethylene are additional illustrative fluoropolymers useful for practicing the present invention.
  • a preferred weatherable polymer for use in the present invention is an alloy of an acrylic polymer and polyvinylidene fluoride, such as "FLUOREX” (a trademark of Rexham Corporation).
  • Urethane polymers useful for practicing the present invention are prepared by reacting a polyisocyanate with a compound containing at least two active hydrogen atom, such as a polyol, a polyamine, or a polyisocyanate.
  • Polyurethane resins for use in the present invention should be selected from resins in which the reactants have been chosen to provide weatherable, thermoformable polymers. Numerous suitable polyurethane resins useful for practicing the present invention are available. Generally, aromatic polyisocyanates tend to yellow, and aliphatic polyisocyanates are more preferred. Particularly noteworthy recent developments in this area are disclosed in U.S. Pat. No.
  • films formed of vinyl polymers such as polyvinylchloride films and films formed from copolymers thereof, may also be used to practice the present invention, though such films are generally not as weatherable as films formed from the previously discussed polymers.
  • the pigmented coating is preferably formed of the same polymer as the preformed film, or may optionally be formed of a different polymer which will bond to the preformed film during the manufacture of the decorative sheet material, as explained below.
  • the adhesive layer 13 carried by the inner surface of the pigmented coating is preferably a film laminated to the pigmented coating. Bonding of the pigmented coating to a film adhesive layer can be achieved with an intermediate bonding layer or layers in accordance with known laminating procedures, and with known adhesives.
  • the adhesive layer is selected to bond to the substrate for which the decorative sheet material is intended. For example, a decorative sheet material having a fusible olefin adhesive layer can be placed in a mold during injection of an olefin resin.
  • Another approach is to bond a PVC film to a fluoropolymer pigment layer with an acrylic adhesive and, in turn, bond the PVC film to an olefin film with a polyester isocyanate adhesive.
  • the pigment layer my also be laminated to an olefin film with a permanent type acrylic pressure-sensitive adhesive.
  • Still another approach is to coat the pigment layer with a soluble olefin resin which adheres thereto and bonds to the injected resin without having or requiring an olefin film layer.
  • a resin is chlorinated polyolefin 343-1 from Eastman Kodak. This resin may be used in conjunction with an acrylic primer or ingredient to bond to desired fluorocarbon films. Corona treatment of the olefin surface to be bonded to the cast film may optionally be used to achieve an optimum bond. Bonding may also be improved by surface treating the cast film, as by corona treatment.
  • the preferred method for making a decorative sheet material of the present invention is by reverse-roll coating, as illustrated in FIG. 3.
  • Reverse-roll coating involves providing a puddle 20 of polymer solution between an applicator roll 21 and a metering roll 22.
  • the rolls (21,22), which rotate in the same direction, are spaced apart a predetermined distance to meter a film 23 of the solution onto the applicator roll.
  • the film on the applicator roll is then applied to a suitable carrier 24, typically a flexible steel band.
  • This film 23a is then sprayed by a spraying apparatus 25 with a liquid pigmented polymer which has reflective flakes suspended therein to form the decorative sheet material described above.
  • the liquid pigmented polymer is sprayed on the film before the film has solidified.
  • the coated film is then dried, removed from the carrier, and--if desired--provided with an adhesive layer 13 in accordance with known procedures. If flakes are present in the pigmented polymer, spraying the pigmented polymer onto the cast film before the cast film has solidified allows the flakes to settle into the cast layer somewhat, and gives a greater depth effect to the film.
  • the foregoing procedure is preferably used to coat the entire undersurface of the cast film.
  • a striking visual effect can be achieved by spraying portions of the undersurface of the cast film with a liquid pigmented polymer, after which the other portions of the undersurface of the cast film is sprayed with a liquid pigmented polymer pigmented a different color than the preceding pigmented polymer.
  • This technique can be used to provide decorative sheet materials which have a two-tone colored appearance, and the coatings can overlap so that the colored regions provided by this technique feather into one another.
  • these two polymer coatings provide an opaque and uninterrupted (in opacity) coating to the undersurface of the substantially clear film.
  • the decorative sheet material of the present invention can be adhered to a supporting substrate in accordance with known laminating or bonding techniques.
  • Illustrative examples of supporting substrates include metal, wood, and molded polymer substrates.
  • a shaped article 30 of the present invention comprises a supporting substrate 31 which has a contoured outer surface, and a decorative sheet material 10 adhered to one side of the substrate so as to conform to the contoured surface of the substrate.
  • particularly suitable shaped articles of the present invention are exterior automobile body parts such as body panels and bumpers.
  • the decorative sheet material can be bonded to molded polymer substrates by placing the sheet material into a mold having a contoured, three-dimensional molding surface. A moldable polymer is then introduced into the mold on one side of the sheet material. The sheet material is then molded into a contoured three-dimensional configuration conforming to the molding surface of said mold, while molding said polymer to form a shaped article with the decorative sheet material adhered to the outer surface thereof.
  • the decorative sheet material includes an adhesive layer 13, as described above, formed of a polymer different from the pigmented coating, wherein the decorative sheet material is placed into the mold with the adhesive layer oriented inwardly away from the molding surface so as to become adhered to the moldable polymer.
  • Suitable polymers for the molded polymer substrate include, for example, polyvinyl chloride, polycarbonate, polystyrene, acrylonitrile-butadienestyrene, polyethylene, polypropylene, polyethylene terephthalate glycol (PETG), nylon, and RIM urethanes.
  • Polyolefin homopolymers and copolymers (ionomers, etc.) are inexpensive thermoplastic resins which have excellent molding properties and are particularly preferred for practicing the present invention.
  • Polypropylene for example, when glass filled and foamed with a blowing agent, has performance properties suitable for structural or engineering uses.
  • Acid copolymers of polyethylene, such as Du Pont's "SURLYN,” are similar in performance and in addition have exceptional toughness.
  • the tear strength of the preformed film is less than the bond strength of the preformed film to the supporting substrate. This will prevent tears from developing in the preformed film, running across the surface of the article, and quickly destroying the article.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Composite Materials (AREA)
  • Laminated Bodies (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

A flexible decorative sheet material for use in surfacing automobile body panels and the like is disclosed. The sheet material is characterized by having the appearance of a base coat/clear coat paint finish. The material comprises a substantially transparent outer layer, and a pigmented coating on the undersurface of the outer layer which is visible therethrough. The pigmented coating preferably has reflective flakes uniformly distributed therein to impart to the sheet material the appearance of a base coat/clear coat paint finish. Also disclosed are shaped articles which have such sheet materials adhered to one side thereof, and a method for making such sheet materials.

Description

FIELD OF THE INVENTION
The present invention relates to sheet materials generally, and particularly relates to a sheet material which can be used to provide a decorative surface on automobile body panels and the like.
BACKGROUND OF THE INVENTION
Among the most important selling features of automobiles is the quality of their painted finish. For this reason, nearly half of automobile assembly costs are devoted to coating operations. See generally, Automobile Coatings: Helping Detroit Woo Consumers, Chemical Week, 30 (July 4, 1984). As aerodynamic body styles become more prevalent, and sharp edges and other decorative detail features continue to be removed from automobile bodies, paint finish will exert an increasingly important influence on the overall decorative appearance of automobiles.
For these reasons, about 70% of the cars sold in the U.S. market are coated with a metallic finish. The difference in brightness and hue obtained when such a finish is observed emphasizes the styling lines of the car, highlighting small curvatures. This effect is known as "flop." The new base coat/clear coat paint finishes, which provide "wet look" paint finishes with or without a metallic appearance, can be used to produce a very high quality metallic finish with excellent flop, and are emerging as the finish of choice in the automobile industry. See, e.g., J. Schrantz, Painting the Corvette, Industrial Finishing, 18 (March, 1984). In addition, because the clear coat protects the base coat, greater quantities of pigments can be incorporated into the base coat without the weatherability of the finish being unacceptably decreased. Base coat/clear coat finishes, however, and particularly metallic finishes, pose significant (and expensive) pollution problems arising from the evaporation of harmful paint solvents. Moreover, they are difficult to provide on plastic automobile body panels, which are becoming a popular mode of construction in the industry. Finally, base coat/clear coat paint finishes in general involve multiple painting steps which are very expensive to perform when high quality standards are maintained.
Accordingly, objects of the present invention are to provide a way to produce automobiles and the like with high quality decorative finishes like a base coat/clear coat finish, which can be used on molded plastic body panels, which does not require expensive painting steps, and which serves to reduce the emission control problems previously faced by manufacturers who wished to produce automobiles with base coat/clear coat finishes.
SUMMARY OF THE INVENTION
The foregoing objects are achieved by a flexible decorative sheet material, disclosed herein, for use in surfacing automobile body panels and the like. This sheet material is characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof. The sheet material comprises a substantially transparent outer layer and a pigmented coating on the undersurface of the outer layer and visible therethrough. The pigmented coating optionally has reflective flakes uniformly distributed therein to impart to the sheet material the appearance of a metallic base coat/clear coat paint finish.
The reflective flakes in the pigmented coating are preferably oriented generally parallel to the outer layer. The outer layer is also preferably formed from a substantially clear film. The pigmented coating is preferably of a thickness less than that of the substantially clear film. The precise thickness of the pigmented coating is, however, selected to impart the specific predetermined appearance to the sheet material which is desired.
Sheet materials of the present invention include dual-color sheet materials which comprise a substantially transparent outer layer and a pigmented coating on the undersurface thereof, wherein the pigmented coating comprises a first pigmented coating on certain portions of the undersurface of the outer layer and visible therethrough, and a second pigmented coating of a different color on certain other portions of the undersurface of the outer layer, which second pigmented coating is also visible therethrough.
Also disclosed herein are shaped articles having a contoured decorative outer surface suitable for use as automobile body panels and the like. The articles comprise a supporting substrate and a decorative sheet material adhered to one side of the substrate, conforming to the contoured surface, to impart to the outer surface the appearance of a base coat/clear coat paint finish. The decorative sheet material is as described above. The supporting substrate, which may be formed of a number of materials, is preferably a rigid metal substrate or a molded polymer substrate.
Also disclosed herein is a method for making a decorative sheet material of the type described above. This method comprises applying to one surface of a substantially clear polymer film, a thin coating of a pigmented polymer. The pigmented polymer preferably has reflective flakes uniformly distributed therein. The method is also described as comprising the steps of forming a substantially clear polymer film on a carrier, coating the film with a pigmented polymer optionally having reflective flakes uniformly distributed therein, and removing the coated film from the carrier.
The polymer film is preferably formed by reverse roll coating a solution of the polymer onto the carrier. The step of applying a thin coating of a pigmented polymer to the film preferably comprises spraying a pigmented polymer which optionally has reflective flakes suspended therein onto the film, and drying the solution to form a thin, pigmented coating. The pigmented polymer is preferably sprayed on the substantially clear film before the film has solidified.
The present invention allows paint and finish handling steps involving solvents to be performed in a central plant, and the "finish" to be shipped, in sheet form, to a number of automobile assembly plants and the like. This sensibly allows solvent emission control problems attendant to such procedures to be handled in a centralized location, reduces the emission control expenses at numerous assembly plants, and serves to reduce the cost and complexity of solvent emissions control in general.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a decorative sheet material of the present invention.
FIG. 2 is a schematic diagram which illustrates the properties of sheet materials of the present invention.
FIG. 3 is a schematic illustration of a method for making decorative sheet materials of the present invention.
FIG. 4 is an article of the present invention with a portion broken away to show the decorative sheet material on the outer surface thereof.
DETAILED DESCRIPTION OF THE INVENTION
A decorative sheet material 10 of the present invention is illustrated in FIG. 1. The sheet material comprises a substantially clear film 11, a pigmented coating 12 on the undersurface of the preformed film, and an adhesive layer 13 carried by the inner surface of the pigmented coating. The pigmented coating has reflective flakes 14 uniformly distributed therein. The pigmented coating is opaque and uninterrupted; the reflective flakes are aluminum flakes or mica flakes. Mica flakes used in the present invention may be untreated, or tinted or otherwise surface treated, as known in the art. The reflective flakes are oriented generally parallel to the preformed film, with the flakes preferably being oriented so the mean angle of inclination of the flakes to the preformed film is less than about 6.5 degrees. The precise limits of the angle of inclination depends on a number of conditions, including the particular type of reflective flake used, the composition of the pigmented coating, and the composition of the preformed film.
The flakes contribute to the "flop" effect described previously. Flop is due to the orientation of the reflective flakes generally parallel to the surface of the finish. As illustrated in FIG. 2, the observer at A' sees the light A reflected by the flakes. A similar situation exists for the observer at B' with light B. Because of the phenomenon of flop, light intensity is lower at B' than A'; i.e., the finish appears darker at B' than A'.
Films 11 for practicing the present invention should be selected so they are pigmentable, thermoformable and weatherable. The film 11 is about 0.5 to about 300 thousandths of an inch thick, and is preferably from about one to about two thousandths of an inch thick. Such films are preferably substantially molecularly unoriented cast films, as opposed to films which have been oriented or biaxially oriented, and are preferably substantially colorless. The cast film is formed before the pigmented coating is applied thereto. Such films are prepared by a number of known liquid casting methods, such as by spreading a solvent solution having a polymer dissolved therein onto a carrier with a casting die, doctor bar, or reverse roll coater, then evaporating the solvent, and then stripping the polymer film from the carrier. The reverse-roll coating method is the preferred method of making liquid cast films for the present invention. Other liquid casting methods are also known and useful for practicing the present invention. In appropriate cases, a plastisol, organosol, or dispersion of the polymer can be cast onto the carrier instead of a solvent solution. For example, polytetrafluoroethylene, which is virtually insoluble, can be liquified and cast as a dispersion. Such liquid cast film processes, and some current uses of cast films, are discussed in Plastics Engineering, at pages 29-33 (May, 1983). Thus, for purposes of the present invention, "substantially molecularly unoriented cast films" are liquid cast films, and not melt cast films or films formed by extrusion.
Polymers suitable for forming such cast films are preferably weatherable polymers selected to provide a pigmented film which will not significantly fade, peel, crack, or chalk when exposed to the environment, for the intended life of the product for which the decorative sheet material is made. A number of known testing procedures, in which objects are exposed to either the natural environment over an extended time or a harsh artificial environment for a short time, are used to determine the weatherability of polymers. Such weatherable polymers include fluoropolymers, acrylate polymers, urethane polymers, vinyl polymers, and blends thereof. Acrylate polymers useful for practicing the present invention are obtained from a variety of acrylic monomers, such as acrylic and methacrylic acids, and their amides, esters, salts, and corresponding nitriles. Particularly suitable monomers for such polymers are methyl methacrylate, ethyl acrylate, and acrylonitrile. The polymers may each be used in the form of homopolymers, or with various other monomers which can be copolymerized therewith. Additional illustrative examples of acrylate polymers useful for the present invention are polyacrylates and polymethacrylates which are homopolymers and copolymers of acrylic acid ester and methacrylic acid ester, such as, for example, polyacrylic acid isobutyl ester, polymethacrylic acid methyl ester, polymethacrylic acid ethylhexyl ester, polyacrylic acid ethyl ester; copolymers of various acrylic acid esters and/or methacrylic acid esters, such as, for example, methacrylic acid methyl ester/acrylic acid cyclohexyl ester copolymers; and copolymers of acrylic acid esters and/or methacrylic acid esters with styrene and/or alphamethylstyrene, as well as the graft polymers and copolymers and polymer mixtures composed of acrylic esters, methacrylic acid esters, styrene and butadiene. A group of transparent, weatherable blends of acrylate polymers and polyvinylidene fluoride polymers useful for practicing the present invention are disclosed in U.S. Pat. No. 3,524,906. The disclosures of this patent, and all other patent references cited herein, are specifically intended to be incorporated herein by reference.
Fluoropolymers useful for practicing the present invention include polymers and copolymers formed from trifluoroethylene, tetrafluoroethylene, hexafluoropropylene, monochlorotrifluoroethylene and dichlorodifluoroethylene. Copolymers of these monomers formed from fluoroolefins such as vinylidene fluoride are also useful. Further illustrative examples of fluoropolymers useful for practicing the present invention include polyvinyl fluoride and polyvinylidene fluoride. The fluoropolymer may be a fluorinated ethylene/propylene copolymer (the easily-fabricated "FEP" resins), or a copolymer of ethylene/chlorotrifluoroethylene such as "HALAR." Vinylidene fluoride/hexafluoropropene and vinylidene fluoride/perfluoro (alkyl vinyl ether) dipolymers and terpolymers with tetrafluoroethylene are additional illustrative fluoropolymers useful for practicing the present invention.
A preferred weatherable polymer for use in the present invention is an alloy of an acrylic polymer and polyvinylidene fluoride, such as "FLUOREX" (a trademark of Rexham Corporation).
Urethane polymers useful for practicing the present invention are prepared by reacting a polyisocyanate with a compound containing at least two active hydrogen atom, such as a polyol, a polyamine, or a polyisocyanate. Polyurethane resins for use in the present invention should be selected from resins in which the reactants have been chosen to provide weatherable, thermoformable polymers. Numerous suitable polyurethane resins useful for practicing the present invention are available. Generally, aromatic polyisocyanates tend to yellow, and aliphatic polyisocyanates are more preferred. Particularly noteworthy recent developments in this area are disclosed in U.S. Pat. No. 4,578,426 (disclosing resins which give coatings resistant to gasoline and having high flexibility, scratch resistance and weather resistance) and U.S. Pat. No. 4,501,852 (disclosing chemical resistant, abrasion resistant, elastic and durable polyurethanes).
In addition, films formed of vinyl polymers, such as polyvinylchloride films and films formed from copolymers thereof, may also be used to practice the present invention, though such films are generally not as weatherable as films formed from the previously discussed polymers.
The pigmented coating is preferably formed of the same polymer as the preformed film, or may optionally be formed of a different polymer which will bond to the preformed film during the manufacture of the decorative sheet material, as explained below. The adhesive layer 13 carried by the inner surface of the pigmented coating is preferably a film laminated to the pigmented coating. Bonding of the pigmented coating to a film adhesive layer can be achieved with an intermediate bonding layer or layers in accordance with known laminating procedures, and with known adhesives. The adhesive layer is selected to bond to the substrate for which the decorative sheet material is intended. For example, a decorative sheet material having a fusible olefin adhesive layer can be placed in a mold during injection of an olefin resin. Another approach is to bond a PVC film to a fluoropolymer pigment layer with an acrylic adhesive and, in turn, bond the PVC film to an olefin film with a polyester isocyanate adhesive. The pigment layer my also be laminated to an olefin film with a permanent type acrylic pressure-sensitive adhesive. Still another approach is to coat the pigment layer with a soluble olefin resin which adheres thereto and bonds to the injected resin without having or requiring an olefin film layer. Such a resin is chlorinated polyolefin 343-1 from Eastman Kodak. This resin may be used in conjunction with an acrylic primer or ingredient to bond to desired fluorocarbon films. Corona treatment of the olefin surface to be bonded to the cast film may optionally be used to achieve an optimum bond. Bonding may also be improved by surface treating the cast film, as by corona treatment.
The preferred method for making a decorative sheet material of the present invention is by reverse-roll coating, as illustrated in FIG. 3. Reverse-roll coating involves providing a puddle 20 of polymer solution between an applicator roll 21 and a metering roll 22. The rolls (21,22), which rotate in the same direction, are spaced apart a predetermined distance to meter a film 23 of the solution onto the applicator roll. The film on the applicator roll is then applied to a suitable carrier 24, typically a flexible steel band. This film 23a is then sprayed by a spraying apparatus 25 with a liquid pigmented polymer which has reflective flakes suspended therein to form the decorative sheet material described above. The liquid pigmented polymer is sprayed on the film before the film has solidified. The coated film is then dried, removed from the carrier, and--if desired--provided with an adhesive layer 13 in accordance with known procedures. If flakes are present in the pigmented polymer, spraying the pigmented polymer onto the cast film before the cast film has solidified allows the flakes to settle into the cast layer somewhat, and gives a greater depth effect to the film.
The foregoing procedure is preferably used to coat the entire undersurface of the cast film. If desired, a striking visual effect can be achieved by spraying portions of the undersurface of the cast film with a liquid pigmented polymer, after which the other portions of the undersurface of the cast film is sprayed with a liquid pigmented polymer pigmented a different color than the preceding pigmented polymer. This technique can be used to provide decorative sheet materials which have a two-tone colored appearance, and the coatings can overlap so that the colored regions provided by this technique feather into one another. In combination, these two polymer coatings provide an opaque and uninterrupted (in opacity) coating to the undersurface of the substantially clear film.
The decorative sheet material of the present invention can be adhered to a supporting substrate in accordance with known laminating or bonding techniques. Illustrative examples of supporting substrates include metal, wood, and molded polymer substrates. As illustrated in FIG. 4, a shaped article 30 of the present invention comprises a supporting substrate 31 which has a contoured outer surface, and a decorative sheet material 10 adhered to one side of the substrate so as to conform to the contoured surface of the substrate. As explained above, particularly suitable shaped articles of the present invention are exterior automobile body parts such as body panels and bumpers.
The decorative sheet material can be bonded to molded polymer substrates by placing the sheet material into a mold having a contoured, three-dimensional molding surface. A moldable polymer is then introduced into the mold on one side of the sheet material. The sheet material is then molded into a contoured three-dimensional configuration conforming to the molding surface of said mold, while molding said polymer to form a shaped article with the decorative sheet material adhered to the outer surface thereof. Preferably, the decorative sheet material includes an adhesive layer 13, as described above, formed of a polymer different from the pigmented coating, wherein the decorative sheet material is placed into the mold with the adhesive layer oriented inwardly away from the molding surface so as to become adhered to the moldable polymer.
Suitable polymers for the molded polymer substrate include, for example, polyvinyl chloride, polycarbonate, polystyrene, acrylonitrile-butadienestyrene, polyethylene, polypropylene, polyethylene terephthalate glycol (PETG), nylon, and RIM urethanes. Polyolefin homopolymers and copolymers (ionomers, etc.) are inexpensive thermoplastic resins which have excellent molding properties and are particularly preferred for practicing the present invention. Polypropylene, for example, when glass filled and foamed with a blowing agent, has performance properties suitable for structural or engineering uses. Acid copolymers of polyethylene, such as Du Pont's "SURLYN," are similar in performance and in addition have exceptional toughness.
Preferably, the tear strength of the preformed film is less than the bond strength of the preformed film to the supporting substrate. This will prevent tears from developing in the preformed film, running across the surface of the article, and quickly destroying the article.
In the drawings and specification, typical preferred embodiments of the invention have been disclosed. Although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims.

Claims (23)

That which is claimed is:
1. A flexible decorative sheet material for use in surfacing automobile body panels . .and the like.!., said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially transparent .Iadd.preformed film .Iaddend.outer layer formed of a substantially molecularly unoriented cast polymer .Iadd.formed from a member selected from the group consisting of fluoropolymers, acrylate polymers, vinyl polymers and blends thereof, .Iaddend.and a pigmented coating on the undersurface of said .Iadd.preformed film .Iaddend.outer layer and visible therethrough, said pigmented coating having reflective flakes uniformly distributed therein and oriented generally parallel to said outer layer to impart to the sheet material the appearance of a base coat/clear coat paint finish.
2. A decorative sheet material as claimed in claim 1, further comprising an adhesive layer carried by said pigmented coating.
3. A decorative sheet material as claimed in claim 1, wherein said pigmented coating comprises a first pigmented coating on certain portions of the undersurface of the outer layer and visible therethrough, and a second pigmented coating of a different color on certain other portions of the undersurface of the outer layer, which second pigmented coating is also visible therethrough.
4. A decorative sheet material as claimed in claim 1, wherein said outer layer is formed from a substantially clear film.
5. A decorative sheet material as claimed in claim 4, wherein said pigmented coating is of a thickness less than said substantially clear film. . .
6. A decorative sheet material as claimed in claim 4, wherein said substantially clear film is formed from a weatherable polymer selected from the group consisting of fluoropolymers, acrylate polymers, urethane polymers, vinyl polymers, and blends thereof..!.
7. A flexible decorative sheet material for use in surfacing automobile body panels . .and the like.!., said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a clear substantially molecularly unoriented weatherable .Iadd.preformed polymer .Iaddend.film .Iadd.formed from a member selected from the group consisting of fluoropolymers, acrylate polymers, vinyl polymers and blends thereof, .Iaddend.and a pigmented coating on the undersurface of said .Iadd.preformed .Iaddend.film and visible therethrough, said pigmented coating having reflective flakes uniformly distributed therein in generally parallel alignment to said film to impart to the sheet material the appearance of a base coat/clear coat paint finish.
8. A decorative sheet material as claimed in claim 7, wherein the mean angle of inclination of said flakes to said film is less than about 6.5 degrees.
9. A decorative sheet material as claimed in claim 7, wherein said pigmented coating is of a thickness less than said film. . .
10. A decorative sheet material as claimed in claim 7, wherein said weatherable film comprises a polymer selected from the group consisting of fluoropolymers, acrylate polymers, urethane polymers, vinyl polymers, and blends thereof..!.
11. A decorative sheet material as claimed in claim 7, further comprising an adhesive layer carried by said pigmented coating.
12. A flexible decorative sheet material for use in surfacing automobile body panels . .and the like.!., said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a clear, substantially colorless and substantially molecularly unoriented cast .Iadd.preformed .Iaddend.polymer film .Iadd.formed from a member selected from the group consisting of floropolymers, acrylate polymers, vinyl polymers and blends thereof, .Iaddend.and a pigmented coating on the undersurface of said .Iadd.preformed .Iaddend.film and visible therethrough, said pigmented coating having a thickness less than said film and including reflective metallic flakes uniformly distributed therein and oriented in generally parallel alignment to said film to impart to the sheet material the appearance of a base coat/clear coat paint finish. . .13. A decorative sheet material as claimed in claim 12, wherein said film comprises a polymer selected from the group consisting of fluoropolymers, acrylate
polymers, urethane polymers, vinyl polymers, and blends thereof..!.14. A decorative sheet material as claimed in claim . .13.!. .Iadd.12.Iaddend.,
wherein said pigmented coating is of a thickness less than said film. 15. A decorative sheet material as claimed in claim 14, wherein the mean angle of inclination of said flakes to said film is less than about 6.5
degrees. 16. A shaped article having a contoured decorative outer surface, comprising a supporting substrate and a decorative sheet material adhered to one side of said substrate and conforming to said contoured surface, said decorative sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially clear .Iadd.preformed film .Iaddend.outer layer formed of a substantially molecularly unoriented cast polymer .Iadd.formed from a member selected from the group consisting of fluoropolymers, acrylate polymers, vinyl polymers and blends thereof, .Iaddend.and a pigmented coating on the undersurface of said .Iadd.preformed film .Iaddend.outer layer and visible therethrough, said pigment coating having reflective flakes uniformly distributed therein to impart to the outer surface of the article the appearance of a base
coat/clear coat paint finish. 17. A shaped article as claimed in claim 16, wherein said substantially clear outer layer comprises a substantially
molecularly unoriented cast film. 18. A shaped article as claimed in claim 16, wherein said pigmented coating has reflective metallic flakes
uniformly distributed therein. 19. A shaped article as claimed in claim
18, wherein said supporting substrate is a rigid metal substrate. 20. A shaped article as claimed in claim 18, wherein said supporting substrate
is a molded polymer substrate. 21. A shaped article as claimed in claim 18, further comprising an adhesive layer carried by said pigmented coating and adhered to said supporting substrate. .Iadd.22. A flexible decorative sheet material for use in surfacing automobile body panels, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially transparent preformed film outer layer formed of a substantially molecularly unoriented cast polymer comprising an alloy of polyvinylidene fluoride and an acrylic polymer and a pigmented coating on the undersurface of said preformed film outer layer and visible therethrough, said pigmented coating having reflective flakes uniformly distributed therein and oriented generally parallel to said outer layer to impart to the sheet material the appearance of a base coat/clear coat paint finish..Iaddend..Iadd.23. A flexible decorative sheet material for use in surfacing automobile body panels, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a clear, substantially molecularly unoriented weatherable thermoformable film comprising an alloy of polyvinylidene fluoride and an acrylic polymer and a thermoformable pigmented coating on the undersurface of said film and visible therethrough, said pigmented coating comprising an alloy of polyvinylidene fluoride and an acrylic polymer and having reflective flakes uniformly distributed therein in generally parallel alignment to said film to impart to the sheet material the appearance of a base
coat/clear coat paint finish..Iaddend..Iadd.24. A shaped article having a contoured decorative outer surface, comprising a molded polymer supporting substrate and a flexible decorative sheet material adhered to one side of said substrate and conforming to said contoured surface, said decorative sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially clear outer layer formed of a substantially molecularly unoriented thermoformable polymer comprising an alloy of polyvinylidene fluoride and an acrylic polymer and a pigmented coating on the undersurface of said outer layer and visible therethrough, said pigment coating comprising an alloy of polyvinylidene fluoride and an acrylic polymer and having reflective flakes uniformly distributed therein to impart to the outer surface of the article the appearance of a base coat/clear coat paint finish..Iaddend..Iadd.25. A shaped article having a contoured decorative outer surface, comprising a molded polymer supporting substrate and a flexible decorative sheet material adhered to one side of said substrate and conforming to said contoured surface, said decorative sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially clear outer layer formed of a substantially molecularly unoriented thermoformable polymer formed from a member selected from the group consisting of fluoropolymers, acrylate polymers, vinyl polymers and blends thereof, a pigmented coating on the undersurface of said outer layer and visible therethrough, said pigmented coating comprising a thermoformable polymer having reflective flakes uniformly distributed therein to impart to the outer surface of the article the appearance of a base coat/clear coat paint finish, and a polyolefin polymer film layer having one surface thereof laminated to said pigmented coating by an intermediate adhesive bonding layer and having the opposite surface thereof adhered to said molded polymer supporting
substrate..Iaddend..Iadd.26. A flexible decorative sheet material for use in surfacing automobile body parts, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially transparent preformed film outer layer formed of a substantially molecularly unoriented cast polymer formed from a member selected from the group consisting of floropolymers, acrylate polymers, vinyl polymers and blends thereof, and a pigmented coating on the under surface of said preformed film outer layer and visible therethrough, said pigmented coating having reflective flakes uniformly distributed therein and oriented generally parallel to said outer layer to impart to the sheet material the appearance of a base coat/clear coat paint finish..Iaddend..Iadd.27. A flexible decorative sheet material for use in surfacing automobile body parts, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a clear, substantially molecularly unoriented weatherable preformed polymer film formed from a member selected from the group consisting of floropolymers, acrylate polymers, vinyl polymers and blends thereof, and a pigmented coating on the under surface of said preformed film and visible therethrough, said pigmented coating having reflective flakes uniformly distributed therein in generally parallel alignment to said film to impart to the sheet material the appearance of a base coat/clear coat paint finish..Iaddend..Iadd.28. A flexible decorative sheet material for use in surfacing automobile body parts, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a clear, substantially colorless and substantially molecularly unoriented cast preformed polymer film formed from a member selected from the group consisting of floropolymers, acrylate polymers, vinyl polymers, and blends thereof, and a pigmented coating on the under surface of said preformed film and visible therethrough, said pigmented coating having a thickness less than said film and including reflective metallic flakes uniformly distributed therein and oriented in generally parallel alignment to said film to impart to the sheet material the appearance of a base coat/clear coat paint finish..Iaddend..Iadd.29. A flexible decorative sheet material for use in surfacing automobile body parts, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially transparent preformed film outer layer formed of a substantially molecularly unoriented cast polymer comprising an alloy of polyvinylidene fluoride and an acrylic polymer and a pigmented coating on the under surface of said preformed film outer layer and visible therethrough, said pigmented coating having reflective flakes uniformly distributed therein and oriented generally parallel to said outer layer to impart to the sheet material the appearance of a base coat/clear coat
paint finish..Iaddend..Iadd.30. A flexible decorative sheet material for use in surfacing automobile body parts, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a clear, substantially molecularly unoriented weatherable thermoformable film comprising an alloy of polyvinylidene fluoride and an acrylic polymer and a thermoformable pigmented coating on the under surface of said film and visible therethrough, said pigmented coating comprising an alloy of polyvinylidene fluoride and an acrylic polymer and having reflective flakes uniformly distributed therein in generally parallel alignment to said film to impart to the sheet material the appearance of a base coat/clear coat paint finish..Iaddend.
US08/317,758 1986-10-28 1994-10-04 Decorative sheet material simulating the appearance of a base coat/clear coat paint finish Expired - Lifetime USRE35739E (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US08/317,758 USRE35739E (en) 1986-10-28 1994-10-04 Decorative sheet material simulating the appearance of a base coat/clear coat paint finish

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US06/924,299 US4810540A (en) 1986-10-28 1986-10-28 Decorative sheet material simulating the appearance of a base coat/clear coat paint finish
US08/317,758 USRE35739E (en) 1986-10-28 1994-10-04 Decorative sheet material simulating the appearance of a base coat/clear coat paint finish

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US06/924,299 Reissue US4810540A (en) 1986-10-28 1986-10-28 Decorative sheet material simulating the appearance of a base coat/clear coat paint finish

Publications (1)

Publication Number Publication Date
USRE35739E true USRE35739E (en) 1998-02-24

Family

ID=25450040

Family Applications (2)

Application Number Title Priority Date Filing Date
US06/924,299 Ceased US4810540A (en) 1986-10-28 1986-10-28 Decorative sheet material simulating the appearance of a base coat/clear coat paint finish
US08/317,758 Expired - Lifetime USRE35739E (en) 1986-10-28 1994-10-04 Decorative sheet material simulating the appearance of a base coat/clear coat paint finish

Family Applications Before (1)

Application Number Title Priority Date Filing Date
US06/924,299 Ceased US4810540A (en) 1986-10-28 1986-10-28 Decorative sheet material simulating the appearance of a base coat/clear coat paint finish

Country Status (7)

Country Link
US (2) US4810540A (en)
EP (1) EP0266109B2 (en)
JP (2) JPH0626718B2 (en)
KR (1) KR930006462B1 (en)
AT (1) ATE91664T1 (en)
CA (1) CA1341177C (en)
DE (1) DE3786640T3 (en)

Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6110547A (en) 1997-04-01 2000-08-29 Grand Polymer Co., Ltd. Method of molding automobile outer trim part, laminated film or sheet for use therein and automobile outer trim part
US6440546B1 (en) 1999-10-13 2002-08-27 Ream Industries Corp. Gloss-adjusting mask layer with particulate filler
US6515717B1 (en) * 1998-08-28 2003-02-04 Reveo, Inc. Computer-based system for producing multi-color multilayer images on substrates using dry multi-colored cholesteric liquid crystal (CLC) pigment materials applied to binder material patterns
US6565955B2 (en) 1999-03-12 2003-05-20 Soliant Llc Bright indium-metallized formable film laminate
US6599566B2 (en) * 2000-04-04 2003-07-29 Kyowa Electric And Chemical Co., Ltd. Ornamental parts and manufacturing method thereof
US6748641B2 (en) * 1999-06-07 2004-06-15 Kansai Paint Co., Ltd. Method of producing a car body having an outer surface formed from a pre-formed patterned plastic film
EP1452426A1 (en) * 2001-11-29 2004-09-01 Compagnie Plastic Omnium Vehicle body part with grained aspect
US6858287B2 (en) 2001-08-10 2005-02-22 Soliant Llc Formable bright film having discontinuous metallic layers
US20050225113A1 (en) * 2004-04-09 2005-10-13 Intier Automotive Inc. Decorative covering for an interior trim component
US7001643B1 (en) * 1999-05-10 2006-02-21 E. I. Dupont De Nemours And Company Decoratively enameled plastic molded parts for motor vehicles
US20070045893A1 (en) * 2005-08-26 2007-03-01 Himanshu Asthana Multilayer thermoplastic films and methods of making
US20080067713A1 (en) * 2004-12-14 2008-03-20 Robert Bordener Method of producing and business model for applying a thin laminate sheet of a decorative material
US20080311357A1 (en) * 2006-12-29 2008-12-18 Collins & Aikman Corporation Laminate construction containing discontinuous metal layer
US20090000063A1 (en) * 2007-06-29 2009-01-01 Leandres Self Guard for vehicle door handles and keyholes
US20090136691A1 (en) * 2005-09-13 2009-05-28 Yamaha Hatsudoki Kabushiki Kaisha Decorative sheet, decorated molded article, and motor vehicle
US20100285308A1 (en) * 2007-10-29 2010-11-11 Merritt William H Composite Articles Having Excellent Adhesion Strength And Methods Of Forming The Same
US10279520B2 (en) * 2014-06-24 2019-05-07 Merck Patent Gmbh Process for the production of three-dimensional patterns in plastic mouldings

Families Citing this family (101)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6321118A (en) * 1986-07-14 1988-01-28 Toyota Motor Corp Reinforced reaction injection molding
US4943680A (en) * 1986-10-28 1990-07-24 Rexham Corporation Method of making a decorative sheet material simulating the appearance of a base coat/clear coat paint finish
US4931324A (en) * 1986-10-28 1990-06-05 Rexham Corporation Decorative sheet material simulating the appearance of a base coat/clear coat paint finish
USRE36457E (en) * 1986-10-28 1999-12-21 Rexam Industries, Corp. Injection molded plastic article with integrated weatherable pigmented film surface
USRE35894E (en) * 1986-10-28 1998-09-08 Rexam Industries Corp. Injection molded plastic article with integral weatherable pigmented film surface
US5342666A (en) * 1986-10-28 1994-08-30 Rexham Industries Corp. Injection molded plastic article with integral weatherable pigmented film surface
US6835267B1 (en) * 1987-03-27 2004-12-28 Avery Dennison Corporation Dry paint transfer process and product
YU46540B (en) 1987-03-27 1993-11-16 Avery International Corp. LAMINATE WHICH CAN BE HEAT-FORMED FOR THE FORMATION OF A THREE-DIMENSIONALLY FORMED OUTER LAYER ON THE OUTER SURFACE OF A CAR PANEL
US5707697A (en) * 1987-03-27 1998-01-13 Avery Dennison Corporation Dry paint transfer product having high DOI automotive paint coat
DE3730051C1 (en) * 1987-09-08 1988-12-08 Goldschmidt Ag Th Carrier sheet suitable for transfer printing for decorative surface coating of flat materials
US4888220A (en) * 1987-09-28 1989-12-19 The Mead Corporation Decorative laminates having 3-dimensional effect
US5114789A (en) * 1987-11-03 1992-05-19 Eastman Kodak Company Protective and decorative sheet material having a transparent topcoat
US6673428B1 (en) * 1987-11-03 2004-01-06 Eastman Kodak Company Flexible and stretchable sheet materials useful in forming protective and decorative coatings
EP0357808A1 (en) * 1988-08-29 1990-03-14 Th. Goldschmidt AG Process for applying decorative coatings to flat materials to produce a marble effect and a suitable plastic-containing carrier sheet for the purpose
US4975306A (en) * 1988-09-19 1990-12-04 The Standard Products Company Color match molding and weatherstrip
US5035940A (en) * 1988-09-19 1991-07-30 Rexham Corporation Aluminum-fluoropolymer laminate
US5192609A (en) * 1988-11-07 1993-03-09 Eastman Kodak Company Thermoformable sheet material
US5100732A (en) * 1988-12-22 1992-03-31 Basf Corporation Coil coating aluminum for use as automotive veneer
US4933237A (en) * 1989-02-17 1990-06-12 Eastman Kodak Company Paint coated sheet material with adhesion promoting composition
US4948654A (en) * 1989-02-27 1990-08-14 Eastman Kodak Company Sheet material useful in forming protective and decorative coatings
US5030514A (en) * 1989-04-27 1991-07-09 Ppg Industries, Inc. Paint composites
US5242751A (en) * 1989-04-27 1993-09-07 Ppg Industries, Inc. Paint composites
US5030513A (en) * 1989-04-27 1991-07-09 Ppg Industries, Inc. Paint composites
US5108836A (en) * 1989-05-22 1992-04-28 Rexham Industries Corp. Weatherable protective surfacing film
US5037680A (en) * 1989-07-10 1991-08-06 Decoma International Inc. Exterior automotive component with pigmented substrate and clear coating
CA2026661A1 (en) * 1989-10-20 1991-04-21 Terry L. Morris Decorative composites and methods for making same
US5125994A (en) * 1989-11-01 1992-06-30 Eastman Kodak Company Thermoforming method
US5262242A (en) * 1990-01-31 1993-11-16 Kansai Paint Co., Ltd. Colored films for use in vacuum forming
US5182141A (en) * 1990-02-13 1993-01-26 Co-Ex-Tec Industries Bilaminate polymer coated metal strip and method for manufacture thereof
US5215826A (en) * 1990-09-25 1993-06-01 Rexham Industries Corp. Surfacing film with thermoformable carrier layer
JP2960174B2 (en) * 1991-02-19 1999-10-06 積水化学工業株式会社 Patterned molded body
US5618593A (en) * 1991-05-08 1997-04-08 The Standard Products Company Weatherstrip molding and method of making same
US5304413A (en) * 1992-04-29 1994-04-19 E. I. Du Pont De Nemours And Company Molded PVF laminar structures
TW224443B (en) * 1992-07-31 1994-06-01 Minnesota Mining & Mfg
US6019923A (en) * 1992-08-25 2000-02-01 Hp-Chemie Pelzer Research & Development Ltd. Process for manufacturing decorable moulded parts
DE4228194A1 (en) * 1992-08-25 1994-03-03 H P Chemie Pelzer Res & Dev Process for the production of decorable moldings
CA2084716C (en) * 1992-11-05 1999-11-16 John R. Johnson Exterior automotive laminate with pressure-sensitive adhesive
US5468532A (en) * 1992-12-10 1995-11-21 Minnesota Mining And Manufacturing Company Multilayer graphic article with color layer
US5977263A (en) * 1992-12-10 1999-11-02 3M Innovative Properties Company Thermal transfer compositions, articles and graphic articles made with same
EP0674593A1 (en) * 1992-12-17 1995-10-04 Minnesota Mining And Manufacturing Company Decorative element
US6071621A (en) * 1993-06-11 2000-06-06 3M Innovative Properties Company Metallized film and decorative articles made therewith
US5498022A (en) * 1994-06-27 1996-03-12 Izumi Corporation Vehicle interior with color coordinated substrate
US6254712B1 (en) 1998-12-08 2001-07-03 Avery Dennison Corporation Extrusion coating process for making high transparency protective and decorative films
US5653927A (en) * 1995-06-07 1997-08-05 Avery Dennison Corporation Control of metallic appearance in automotive cast paint films
ZA964731B (en) 1995-06-07 1997-01-07 Avery Dennison Corp A Legal Bo Extrusion coating process for making protective and decorative films
US20040209057A1 (en) * 1995-06-07 2004-10-21 Enlow Howard H. Extruded polymeric high transparency films
US6113838A (en) * 1995-06-07 2000-09-05 Avery Dennison Corporation Control of metallic appearance in automotive cast paint films
WO1996040519A1 (en) 1995-06-07 1996-12-19 Avery Dennison Corporation Extrusion process for protective coatings for outdoor siding panels and the like
WO1997018075A1 (en) * 1995-11-10 1997-05-22 Austria Card Plastikkarten Und Ausweissysteme Gesellschaft Mbh Cover laminate for plastic cards
US5870643A (en) * 1995-12-28 1999-02-09 Eastman Kodak Company Single-use flash cameras with reflector or siren
US6068896A (en) * 1996-02-29 2000-05-30 Toyoda Gosei Co., Ltd. Molded colored articles
US5985079A (en) * 1996-03-28 1999-11-16 Rexam Industries Corp. Flexible composite surfacing film and method for producing same
US6251506B1 (en) 1997-05-22 2001-06-26 Ato Fina Chemicals, Inc. Polyvinylidene fluoride coated articles from resins formable at high temperatures
US6866938B2 (en) 1997-07-22 2005-03-15 Nissha Printing Co., Ltd. Foil-detecting sheet and method of producing a foil-decorated resin article using the same
EP0933183B1 (en) 1997-07-22 2008-11-19 Nissha Printing Co., Ltd. Sheet for molded-in foil decoration and method of producing molded resin having molded-in foil decoration by using the sheet
JP3540921B2 (en) * 1997-09-18 2004-07-07 豊田合成株式会社 Resin molding
US6096396A (en) * 1998-01-21 2000-08-01 Rexam Industries Corp. Decorative sheet material suitable for use as a flexible weatherable paint film or decal
CA2266873C (en) * 1998-04-09 2002-05-28 Rexam Industries Corp. Film finishing system with design option
JP2000038459A (en) 1998-05-20 2000-02-08 Sumitomo Chem Co Ltd Film or sheet, laminated structure and use thereof
CA2279737C (en) 1998-08-06 2004-04-27 Naoya Haruta Decorative film for use in platics molding, process for preparing the same and injection-molded part by use of the same
US6399193B1 (en) 1998-12-18 2002-06-04 The University Of Massachusetts Lowell Surfacing laminate with bonded with pigmented pressure sensitive adhesive
US6723427B1 (en) 1999-06-21 2004-04-20 Avery Dennison Corporation Fade printed decorative sheets and methods and apparatus for making the same
WO2000078539A1 (en) * 1999-06-21 2000-12-28 Avery Dennison Corporation Fade printed decorative sheets and methods and apparatus for making the same
JP3661583B2 (en) 2000-03-14 2005-06-15 日産自動車株式会社 Acrylic resin composition, coated film molded resin plate using the same, and surface covering material for solar cell panel
ES2244615T5 (en) 2000-04-14 2012-06-15 E.I. Du Pont De Nemours And Company Multilayer coextruded ionomeric decorative surface
US20030138635A1 (en) * 2000-07-11 2003-07-24 Naoya Haruta Multi-layer application film and method of laminating the same
CN1244616C (en) * 2000-07-11 2006-03-08 关西涂料株式会社 Coated film and method of laninating the same
JP4618858B2 (en) * 2000-10-04 2011-01-26 関西ペイント株式会社 Coating method for automobile body
US6607831B2 (en) 2000-12-28 2003-08-19 3M Innovative Properties Company Multi-layer article
US6998084B2 (en) * 2001-02-16 2006-02-14 Daimlerchrysler Corporation Co-extruded pigmented/clear coated polymeric coating for an article such as automotive exterior body panels
US6666946B2 (en) 2001-03-14 2003-12-23 3M Innovative Properties Company Method of high speed coating pigment-containing liquid coating materials
DE10140205A1 (en) * 2001-08-16 2003-03-06 Basf Coatings Ag Color and / or effect films, processes for their production and their use
WO2003066761A2 (en) * 2002-02-04 2003-08-14 Avery Dennison Corporation Topcoat compositions, coated substrates and method
US20030190434A1 (en) * 2002-04-05 2003-10-09 Byers Alicia D. Process for applying automotive quality effect coatings to metal substrates
JP3982755B2 (en) * 2002-12-16 2007-09-26 本田技研工業株式会社 Decorative article
JP2004202816A (en) * 2002-12-25 2004-07-22 Honda Motor Co Ltd Coating substitute film and method for pasting the film
US7512498B2 (en) * 2002-12-31 2009-03-31 Intel Corporation Streaming processing of biological sequence matching
WO2004067249A2 (en) * 2003-01-27 2004-08-12 Robert Lafave Decorative system composite and method
US6838520B2 (en) * 2003-05-29 2005-01-04 Equistar Chemicals, Lp Adhesives for fluoropolymer films and structures containing same
US20050106386A1 (en) * 2003-10-07 2005-05-19 Vogel Randall A. Thermoformable multi-layer sheet
CN1890095A (en) * 2003-10-07 2007-01-03 纳幕尔杜邦公司 Multi-layer lonomer sheet having improved weathering
MXPA06003825A (en) * 2003-10-07 2006-06-14 Du Pont Multi-layer sheet comprising an ionomer layer.
US20050175794A1 (en) * 2003-11-26 2005-08-11 Dathe Paul J. Using multilayer thermoformable sheetstock and/or films to form body panels
US20050147799A1 (en) * 2003-12-16 2005-07-07 Robert Bordener Article, method of producing and business model for applying a thin laminate sheet of a decorative material
DE102004010787A1 (en) * 2004-03-05 2005-09-22 Basf Coatings Ag Method for producing a multilayer film F and its use
US7853454B2 (en) * 2004-12-02 2010-12-14 Laminate Products, Inc. Method of producing a paint film part
EP1937454B1 (en) * 2005-10-21 2016-05-25 Entrotech, Inc. Protective sheets, articles, and methods
US8545960B2 (en) * 2006-10-23 2013-10-01 Entrotech, Inc. Articles comprising protective sheets and related methods
US10035932B2 (en) * 2007-09-25 2018-07-31 Aero Advanced Paint Technology, Inc. Paint replacement films, composites therefrom, and related methods
DE102007054579B4 (en) * 2007-11-15 2013-03-21 Lisa Dräxlmaier GmbH Piano lacquer look through foil insert
US10981371B2 (en) 2008-01-19 2021-04-20 Entrotech, Inc. Protected graphics and related methods
JP5324642B2 (en) 2008-03-25 2013-10-23 スリーエム イノベイティブ プロパティズ カンパニー Paint film composite and method for producing the same
US8551279B2 (en) * 2008-03-25 2013-10-08 3M Innovative Properties Company Multilayer articles and methods of making and using the same
PL2401149T3 (en) * 2009-02-25 2017-07-31 Avery Dennison Corporation Method for making multi-layer print media by extrusion coating
IT1396079B1 (en) * 2009-10-16 2012-11-09 Zanini Holding S P A PROCESS OF MANUFACTURE OF A DECORATIVE ELEMENT, PARTICULARLY INTENDED FOR USE AS AN EMBLEM ON A MOTOR VEHICLE.
US8910998B1 (en) * 2014-03-27 2014-12-16 Srinivas S. Devathi Systems and methods for altering the color, appearance, or feel of a vehicle surface
EP4328280A3 (en) 2016-09-20 2024-05-15 PPG Advanced Surface Technologies, LLC Paint film appliques with reduced defects, articles, and methods
EP3676087A1 (en) * 2017-08-29 2020-07-08 Lubrizol Advanced Materials, Inc. Composite laminate including a thermoplastic polyurethane film layer
CN111246998B (en) 2017-10-20 2022-06-07 帝人株式会社 Method for manufacturing metal member, resin member, and exterior member
JP7137148B2 (en) 2019-02-25 2022-09-14 東洋紡株式会社 oriented polyester film
JP7284917B2 (en) 2019-09-13 2023-06-01 東洋紡株式会社 Coating Substitute Films, Composite Films, Laminated Metal Sheets, Processed Products and Molded Products

Citations (28)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2880542A (en) * 1957-05-29 1959-04-07 Abraham S Butterweich Decorative sheeting with multi-color sparkle effect
US3524906A (en) * 1967-10-10 1970-08-18 American Cyanamid Co Transparent and weatherable polymer blends of acrylate polymers and polyvinylidene fluoride
US3549405A (en) * 1965-03-29 1970-12-22 Dow Chemical Co Iridescent resinous film bodies and a substrate coated therewith
GB1232971A (en) * 1967-04-28 1971-05-26
US3679510A (en) * 1970-08-06 1972-07-25 Riegel Paper Corp Weather resistant moldable laminate
US3697070A (en) * 1970-06-19 1972-10-10 Mobil Oil Corp Metallizing coating compositions
US3806397A (en) * 1972-06-08 1974-04-23 Kukoff J Decorative articles
US3949139A (en) * 1972-02-10 1976-04-06 Avery Corporation Laminar reflective platelets and compositions and articles comprising them
US3988494A (en) * 1972-04-10 1976-10-26 Mobil Oil Corporation Metallizing coating compositions
US4126727A (en) * 1976-06-16 1978-11-21 Congoleum Corporation Resinous polymer sheet materials having selective, decorative effects
US4215170A (en) * 1978-02-28 1980-07-29 Eurographics Holding, N. V. Metallization process
US4263077A (en) * 1978-05-12 1981-04-21 Avery International Corporation In-press transfer painting of hardboard
US4307149A (en) * 1979-11-05 1981-12-22 Columbia Ribbon & Carbon Mfg. Co., Inc. Transfer elements and process for making same
US4311757A (en) * 1979-06-06 1982-01-19 Formica Corporation Decorative metallic laminates
GB2084513A (en) * 1980-10-03 1982-04-15 Nissan Motor Sheet for ornamentation
US4359491A (en) * 1980-12-31 1982-11-16 Jin An Industrial Co., Ltd. Process for the preparation of a thermal transferable twinkling pattern
US4396680A (en) * 1981-03-04 1983-08-02 E. I. Du Pont De Nemours And Co. Substrate coated with crater resistant acrylic enamel
JPS58136438A (en) * 1982-02-09 1983-08-13 モダン・プラスチック工業株式会社 Automotive exterior adhesive sheet and its manufacturing method
US4409280A (en) * 1981-09-21 1983-10-11 Mannington Mills Decorative surface coverings
US4451522A (en) * 1980-10-29 1984-05-29 Nordipa Ag Transferable enamel sheet and method and apparatus for its fabrication
JPS59227447A (en) * 1983-06-10 1984-12-20 大洋製鋼株式会社 Precoated metallic plate
US4501852A (en) * 1983-06-20 1985-02-26 Mobay Chemical Corporation Stable, aqueous dispersions of polyurethane-ureas
US4533592A (en) * 1984-08-02 1985-08-06 Minnesota Mining And Manufacturing Company Thermally stable flame retardant reflective and retroreflective trim
US4578426A (en) * 1983-06-24 1986-03-25 Basf Aktiengesellschaft Production of coatings
JPS62138213A (en) * 1985-12-12 1987-06-22 Dainippon Ink & Chem Inc Manufacturing method of colored film for pasting
US4678690A (en) * 1986-01-10 1987-07-07 Rexham Corporation Premasked decal
EP0230364A2 (en) * 1986-01-14 1987-07-29 Minnesota Mining And Manufacturing Company Composite useful for paint transfer and method of use and preparation thereof
US4769100A (en) * 1986-09-22 1988-09-06 General Motors Corporation Method of applying carrier films prepainted with metallic paint to automobile body panels

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4248762A (en) * 1977-07-18 1981-02-03 Stauffer Chemical Company Pressure sensitive products with decorative appearance
US4264654A (en) * 1978-07-24 1981-04-28 Hajime Okazaki Method of producing a metallic-tone coating on a metal substrate
JPS58133868A (en) * 1982-02-05 1983-08-09 Yoshino Kogyosho Co Ltd Structure of decorative painting on surface of synthetic resin molding and formation of said decorative painting
EP0099335B1 (en) * 1982-07-10 1986-02-05 Ciba-Geigy Ag A method of providing a protected layer
JPS60110379A (en) * 1983-11-17 1985-06-15 Toyota Motor Corp Method for coating polypropylene resin parts

Patent Citations (29)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2880542A (en) * 1957-05-29 1959-04-07 Abraham S Butterweich Decorative sheeting with multi-color sparkle effect
US3549405A (en) * 1965-03-29 1970-12-22 Dow Chemical Co Iridescent resinous film bodies and a substrate coated therewith
GB1232971A (en) * 1967-04-28 1971-05-26
US3524906A (en) * 1967-10-10 1970-08-18 American Cyanamid Co Transparent and weatherable polymer blends of acrylate polymers and polyvinylidene fluoride
US3697070A (en) * 1970-06-19 1972-10-10 Mobil Oil Corp Metallizing coating compositions
US3679510A (en) * 1970-08-06 1972-07-25 Riegel Paper Corp Weather resistant moldable laminate
US3949139A (en) * 1972-02-10 1976-04-06 Avery Corporation Laminar reflective platelets and compositions and articles comprising them
US3988494A (en) * 1972-04-10 1976-10-26 Mobil Oil Corporation Metallizing coating compositions
US3806397A (en) * 1972-06-08 1974-04-23 Kukoff J Decorative articles
US4126727A (en) * 1976-06-16 1978-11-21 Congoleum Corporation Resinous polymer sheet materials having selective, decorative effects
US4215170A (en) * 1978-02-28 1980-07-29 Eurographics Holding, N. V. Metallization process
US4263077A (en) * 1978-05-12 1981-04-21 Avery International Corporation In-press transfer painting of hardboard
US4311757A (en) * 1979-06-06 1982-01-19 Formica Corporation Decorative metallic laminates
US4307149A (en) * 1979-11-05 1981-12-22 Columbia Ribbon & Carbon Mfg. Co., Inc. Transfer elements and process for making same
GB2084513A (en) * 1980-10-03 1982-04-15 Nissan Motor Sheet for ornamentation
US4451522A (en) * 1980-10-29 1984-05-29 Nordipa Ag Transferable enamel sheet and method and apparatus for its fabrication
US4359491A (en) * 1980-12-31 1982-11-16 Jin An Industrial Co., Ltd. Process for the preparation of a thermal transferable twinkling pattern
US4396680A (en) * 1981-03-04 1983-08-02 E. I. Du Pont De Nemours And Co. Substrate coated with crater resistant acrylic enamel
US4409280A (en) * 1981-09-21 1983-10-11 Mannington Mills Decorative surface coverings
JPS58136438A (en) * 1982-02-09 1983-08-13 モダン・プラスチック工業株式会社 Automotive exterior adhesive sheet and its manufacturing method
JPS59227447A (en) * 1983-06-10 1984-12-20 大洋製鋼株式会社 Precoated metallic plate
US4501852A (en) * 1983-06-20 1985-02-26 Mobay Chemical Corporation Stable, aqueous dispersions of polyurethane-ureas
US4578426A (en) * 1983-06-24 1986-03-25 Basf Aktiengesellschaft Production of coatings
US4533592A (en) * 1984-08-02 1985-08-06 Minnesota Mining And Manufacturing Company Thermally stable flame retardant reflective and retroreflective trim
JPS62138213A (en) * 1985-12-12 1987-06-22 Dainippon Ink & Chem Inc Manufacturing method of colored film for pasting
US4678690A (en) * 1986-01-10 1987-07-07 Rexham Corporation Premasked decal
EP0230364A2 (en) * 1986-01-14 1987-07-29 Minnesota Mining And Manufacturing Company Composite useful for paint transfer and method of use and preparation thereof
US4818589A (en) * 1986-01-14 1989-04-04 Minnesota Mining And Manufacturing Company Paint transfer article and methods of preparation and use thereof
US4769100A (en) * 1986-09-22 1988-09-06 General Motors Corporation Method of applying carrier films prepainted with metallic paint to automobile body panels

Non-Patent Citations (13)

* Cited by examiner, † Cited by third party
Title
"Automotive Coatings Helping Detroit Woo Consumers", Chemical Week, Jul. 4, 1994.
"Automotive Coatings--Helping Detroit woo consumers", Chemical Week, Jul. 4, 1984, p. 31.
Automotive Coatings Helping Detroit woo consumers , Chemical Week, Jul. 4, 1984, p. 31. *
Automotive Coatings Helping Detroit Woo Consumers , Chemical Week, Jul. 4, 1994. *
Avery s Answer and Counterclaim, dated Jan. 26, 1995. *
Avery s Motion to Dismiss to be Treated as a Motion for Summary Judgment, and supporting documents, filed Oct. 20, 1994. *
Avery's Answer and Counterclaim, dated Jan. 26, 1995.
Avery's Motion to Dismiss to be Treated as a Motion for Summary Judgment, and supporting documents, filed Oct. 20, 1994.
Chemical Week, Jul. 4, 1984, p. 30, Automotive Coatings: Helping Detroit Woo Consumers. *
Plastic Coating Printing Handbook. *
Polymers Paint Colour Journal, Oct. 29, 1980, p. 796, the Orientation of Aluminium. Pigments in Automotive Finishes, contributed by Toyo Aluminium K.K. *
S. Ricklin, "Solvent-cast films", Plastics Engineering, May 1983, pp. 29-33.
S. Ricklin, Solvent cast films , Plastics Engineering, May 1983, pp. 29 33. *

Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6110547A (en) 1997-04-01 2000-08-29 Grand Polymer Co., Ltd. Method of molding automobile outer trim part, laminated film or sheet for use therein and automobile outer trim part
US6515717B1 (en) * 1998-08-28 2003-02-04 Reveo, Inc. Computer-based system for producing multi-color multilayer images on substrates using dry multi-colored cholesteric liquid crystal (CLC) pigment materials applied to binder material patterns
US6565955B2 (en) 1999-03-12 2003-05-20 Soliant Llc Bright indium-metallized formable film laminate
US7001643B1 (en) * 1999-05-10 2006-02-21 E. I. Dupont De Nemours And Company Decoratively enameled plastic molded parts for motor vehicles
US6748641B2 (en) * 1999-06-07 2004-06-15 Kansai Paint Co., Ltd. Method of producing a car body having an outer surface formed from a pre-formed patterned plastic film
US6440546B1 (en) 1999-10-13 2002-08-27 Ream Industries Corp. Gloss-adjusting mask layer with particulate filler
US6599566B2 (en) * 2000-04-04 2003-07-29 Kyowa Electric And Chemical Co., Ltd. Ornamental parts and manufacturing method thereof
US6858287B2 (en) 2001-08-10 2005-02-22 Soliant Llc Formable bright film having discontinuous metallic layers
EP1452426A1 (en) * 2001-11-29 2004-09-01 Compagnie Plastic Omnium Vehicle body part with grained aspect
US20050225113A1 (en) * 2004-04-09 2005-10-13 Intier Automotive Inc. Decorative covering for an interior trim component
US7159914B2 (en) * 2004-04-09 2007-01-09 Intier Automotive Inc. Decorative covering for an interior trim component
US20080067713A1 (en) * 2004-12-14 2008-03-20 Robert Bordener Method of producing and business model for applying a thin laminate sheet of a decorative material
US20070045893A1 (en) * 2005-08-26 2007-03-01 Himanshu Asthana Multilayer thermoplastic films and methods of making
US20090136691A1 (en) * 2005-09-13 2009-05-28 Yamaha Hatsudoki Kabushiki Kaisha Decorative sheet, decorated molded article, and motor vehicle
US20080311357A1 (en) * 2006-12-29 2008-12-18 Collins & Aikman Corporation Laminate construction containing discontinuous metal layer
US20090000063A1 (en) * 2007-06-29 2009-01-01 Leandres Self Guard for vehicle door handles and keyholes
US20100285308A1 (en) * 2007-10-29 2010-11-11 Merritt William H Composite Articles Having Excellent Adhesion Strength And Methods Of Forming The Same
US10279520B2 (en) * 2014-06-24 2019-05-07 Merck Patent Gmbh Process for the production of three-dimensional patterns in plastic mouldings

Also Published As

Publication number Publication date
DE3786640T3 (en) 2003-05-22
KR930006462B1 (en) 1993-07-16
EP0266109B1 (en) 1993-07-21
CA1341177C (en) 2001-01-30
EP0266109A2 (en) 1988-05-04
JPS63123469A (en) 1988-05-27
JPH0852416A (en) 1996-02-27
DE3786640T2 (en) 1994-03-31
KR880004948A (en) 1988-06-27
US4810540A (en) 1989-03-07
EP0266109B2 (en) 2002-09-25
ATE91664T1 (en) 1993-08-15
DE3786640D1 (en) 1993-08-26
JP2657050B2 (en) 1997-09-24
EP0266109A3 (en) 1989-05-31
JPH0626718B2 (en) 1994-04-13

Similar Documents

Publication Publication Date Title
USRE35739E (en) Decorative sheet material simulating the appearance of a base coat/clear coat paint finish
US4931324A (en) Decorative sheet material simulating the appearance of a base coat/clear coat paint finish
US4943680A (en) Method of making a decorative sheet material simulating the appearance of a base coat/clear coat paint finish
US5514427A (en) Injection molded plastic article with integral weatherable pigmented film surface
EP0266107B2 (en) Injection molded plastic article with integral weatherable pigmented film surface
USRE36457E (en) Injection molded plastic article with integrated weatherable pigmented film surface
CA1337795C (en) Dry paint transfer process and product
US6835267B1 (en) Dry paint transfer process and product
US6966962B2 (en) Dry paint transfer-lamination process for making high DOI automotive body panels
USRE35894E (en) Injection molded plastic article with integral weatherable pigmented film surface
US6551432B1 (en) Dry paint transfer process and product
EP0419001A1 (en) Thermoformable laminate films and processes
JP2657050C (en)

Legal Events

Date Code Title Description
AS Assignment

Owner name: REXAM INDUSTRIES CORP., NORTH CAROLINA

Free format text: CHANGE OF NAME;ASSIGNOR:REXHAM INDUSTRIES CORP.;REEL/FRAME:007824/0740

Effective date: 19950518

FPAY Fee payment

Year of fee payment: 12

AS Assignment

Owner name: REXAM DELAWARE CORPORATION, NORTH CAROLINA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:REXAM IMAGE PRODUCTS, INC.;REEL/FRAME:013221/0277

Effective date: 20020610

Owner name: REXAM IMAGE PRODUCTS INC., NORTH CAROLINA

Free format text: MERGER;ASSIGNOR:REXAM INDUSTRIES CORP.;REEL/FRAME:013221/0272

Effective date: 20000713

AS Assignment

Owner name: SOLIANT LLC, SOUTH CAROLINA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:REXAM DELAWARE CORPORATION;REEL/FRAME:013231/0481

Effective date: 20020813