Abstract: A method of making thermoplastic formable sheets laminated with a decorative film, such as one or more layers of glossy clear coat bonded to a layer of pigment containing paint. The method involves providing a thermoplastic formable plastic sheet; applying, on a surface of the plastic sheet, a layer of unsolidified decorative colorant material which forms a decorative first film; curing (if necessary) the decorative material layer to form the adherent first film bonded to the sheet; and applying, on the first film, a unsolidified second film for forming a high quality outer surface covering the decorative first film. Optionally, the decorative sheet may have a first protective layer of thermoformable plastic film removably fixed to the decorative material to protect it from damage during forming of the sheet into a formed part or panel. For automotive body trim parts or body panels, the formable laminated sheet preferably has a thickness of from generally 0.065 to generally 0.

Abstract: A decorative film, such as a film of pigmented paint or a colored thermoplastic layer covered by a film of clear coat, has the outer (clear coat) surface protected by a removably fixed thermoformable first protective film layer. A flexible plastic film forming a second protective layer is removably fixed to the first layer. The underlying decorative film may be laminated to a thin wall or thick wall thermoplastic formable sheet. The second protective layer is removed just prior to forming of the laminated decorative sheet, carrying with the protective film any surface damage marks or irregularities. Subsequent compression forming, as into a body panel or trim part, thus will not cause marking of the decorative film from transfer of damage marks since the underlying first protective layer remains undamaged. The first protective layer may remain in place during assembly of the formed body panel or trim part into a vehicle, and thereafter until delivery of the vehicle by a dealer to a customer.

Abstract: Method and apparatus for forming thick wall plastic components laminated with formable decorative film layers. A thermoformable thick wall plastic sheet in the range of 0.065 to about 0.300 inches thick over at least half its area is provided having a thermoformable decorative dry film coating on one side forming an outer surface of the laminated sheet. The sheet is peripherally supported in an open center rack, heated in one or more ovens to forming temperature and formed by a combination of compression and, preferably, vacuum forming with subsequent trimming of excess material to form a finished component with a high quality finish suitable for automotive body use. The compression and vacuum forming steps may be interchangeably performed in order and provide for high quality finish on the outer surface with shaping of reentrant wall portions on the inner side. Any suitable form of laminated sheet may be formed by the apparatus and method.