Abstract: A flexible and stretchable sheet material that is capable of being stretched to conform to a three-dimensional substrate to form a protective and decorative coating thereon is comprised of a thin flexible support having adhered thereto a protective and decorative layer such as a paint layer comprising a colorant incorporated in a film-forming binder. Both the support and the protective and decorative layer are characterized by a very high degree of thickness uniformity and the sheet material exhibits a high level of surface uniformity, an ability to undergo substantial elongation, and a substantially uniform quality and appearance; whereby it can be stretched and bent in the process of bonding it to a substrate and still achieve a defect-free coating of uniformly attractive appearance.

Abstract: Method and apparatus for making thermoplastic web from polyester or polyester blends for subsequent aqueous coating without requirement of an undercoat or primer coat for adhesion of subsequent coatings. Feedstock pellets of polymer, such as polyethylene terephthalate or polyethylene naphthalate, are melted in a screw extruder. Molten polymer is extruded from an extrusion die as a thick, high-viscosity ribbon, which is tempered and stretched in both the machine direction and the transverse direction to form a web of biaxially-oriented polymer of the desired width and thickness. The web is heated to a temperature above T.sub.g to set the biaxial orientation and then is glow discharge treated by passing it through an in-line glow discharge apparatus at atmospheric pressure wherein a stable glow discharge is produced in a gas mixture containing helium between two electrodes connected by an alternating power source operating at a voltage between 0.5 kV and 20 kV at a frequency between 60 Hz and 40 MHz.

Abstract: A protective and decorative sheet material for covering substrates comprisesa flexible carrier film,a paint layer adhered to one surface of the carrier film containing light reflective flakes;a transparent polymeric topcoat overlying and adhered to the paint layer having a thickness of at least about 0.1 millimeter.The sheet material has a substantially unstressed relaxed state and a relaxed area and is heat softenable to a substantially plastic state in which it is extendable to an extended state having an extended area up to at least 50% greater than the relaxed area. The paint and topcoat layers have substantially uniform quality and appearance in both the relaxed and extended states. The thick transparent topcoat provides improved retention of gloss and distinctness of image when the sheet material is stretched. A method of preparing the sheet material comprises the step of extruding in laminar flow a layer of a crosslinkable transparent topcoat composition over the paint layer.

Abstract: A protective and decorative polymeric sheet material for bonding to substrates by thermoforming comprises a flexible carrier film, a paint layer on one surface of the carrier film containing a colorant or light reflective flakes or both; and a transparent topcoat overlying the paint layer. At least a portion of the transparent topcoat is a rubbery cushioning layer formed of a non-crosslinked, or lightly crosslinked polymeric composition of low Tg.The sheet material has an unextended state and is heat softenable to a plastic state in which it is extendable to an extended state at least 50% greater in area than the unextended state. The paint and topcoat layers have substantially uniform quality and appearance in both the unextended and extended states. In a preferred embodiment, the thickness of the transparent topcoat is at least 0.1 millimeter. The thick topcoat provides improved retention of gloss and distinctness of image when the sheet material is stretched.

Abstract: A flexible and stretchable sheet material that is capable of being stretched to conform to a three-dimensional substrate to form a protective and decorative coating thereon is comprised of a thin flexible support having adhered thereto a protective and decorative layer such as a paint layer comprising a colorant incorporated in a film-forming binder. Both the support and the protective and decorative layer are characterized by a very high degree of thickness uniformity and the sheet material exhibits a high level of surface uniformity, an ability to undergo substantial elongation, and a substantially uniform quality and appearance; whereby it can be stretched and bent in the process of bonding it to a substrate and still achieve a defect-free coating of uniformly attractive appearance.

Abstract: An adhesive-coated thermoplastic film is stretched and bonded to a three-dimensional substrate by vacuum thermoforming at a lower than normal temperature, at which the film has an elastic modulus of at least 10.sup.9 dynes/cm.sup.2, followed by moderate heat treatment of the resulting laminated article. The procedure is especially useful in avoiding air entrapment and peel-back in the thermoforming of a paint-coated film on exterior body panels for automobiles.

Abstract: A protective and decorative sheet material for covering substrates comprisesa flexible carrier film,a paint layer adhered to one surface of the carrier film containing light reflective flakes;a transparent polymeric topcoat overlying and adhered to the paint layer having a thickness of at least about 0.1 millimeter.The sheet material has a substantially unstressed relaxed state and a relaxed area and is heat softenable to a substantially plastic state in which it is extendable to an extended state having an extended area up to at least 50% greater than the relaxed area. The paint and topcoat layers have substantially uniform quality and appearance in both the relaxed and extended states. The thick transparent topcoat provides improved retention of gloss and distinctness of image when the sheet material is stretched. A method of preparing the sheet material comprises the step of extruding in laminar flow a layer of a crosslinkable transparent topcoat composition over the paint layer.

Abstract: A flexible, thermoformable sheet material is bonded to a three-dimensional substrate to form a protective and decorative surface having the appearance of a basecoat-clearcoat automotive finish by a method which includes sequentially thermoforming a thermoplastic paint-coated basecoat sheet and a thermoplastic clearcoat sheet onto the substrate.

Abstract: A protective web is releasably laminated to an adhesive-coated stretchable web by continuously drawing the webs at differential degrees of tensile strain into laminating contact in the nip formed by a resilient and a non-resilient roller.

Abstract: A continuous method for making a protective and decorative sheet material comprises:(A) forming a highly reflective, specular metal layer on a continuously moving web of a thermoformable carrier film; and(B) continuously bending and drawing the web biaxially around first and second non-parallel cracking members to create in the metal layer a pattern of microscopic cracks which, when the sheet material is stretched and thermoformed, is capable of exhibiting a brushed metal appearance.

Abstract: In the manufacture of a paint-coated stretchable film which is useful as a covering for automobile panels and other articles, a stretchable carrier film is formed by extruding a thermoplastic polymer composition onto a heat resistant temporary carrier film. The extruded layer is coated with paint or other layers and dried initially at a moderate temperature and finally at a high temperature which exceeds the heat deformation temperature of the stretchable carrier film but not of the heat resistant temporary carrier film. This shortens drying time and/or reduces residual solvents in the dried layers. The temporary carrier film, which is later stripped away, resists deformation of the laminate as it is drawn under tensile stress through the coating and high temperature drying stages.

Abstract: A tie-coat composition for preparing paint-coated, stretchable polyester which can be bonded to automobile panels. The tie-coat contains a non-ionic, fluorinated surfactant which reduces product non-uniformities.

Abstract: A latex paint containing water and one or more higher boiling organic solvents is coated on a carrier film and dried by a process which yields a dried paint layer free of bubble defects. The film is passed continuously through a series of at least three drying stages in contact with warm, moderately humid air and more than half of the heat required for evaporation is supplied to the underside of the film. Drying conditions in at least each of the first three stages are controlled to maintain a film temperature profile which causes the water to evaporate at a moderate rate but more rapidly than the organic solvents, thus achieving coalescence of the paint and avoiding the trapping of liquids in a surface-hardened paint layer.

Abstract: A process for continuous coating of a reactive clearcoat composition on a painted-coated moving plastic film web by means of a laminar flow extrusion coating hopper wherein the reactive components of the composition are fed continuously to a mixing zone and mixed shortly before the composition is coated on the film surface.