Abstract: A process for making functional or decorative flakes or platelets economically and at high production rates comprises applying a multi-layer sandwich of vapor deposited metal and release coats in alternating layers to a rotating chilled drum or suitable carrier medium contained in a vapor deposition chamber. The alternating metallized layers are applied by vapor deposition and the intervening release layers are preferably solvent soluble thermoplastic polymeric materials applied by vapor deposition sources contained in the vapor deposition chamber. The multi-layer sandwich built up in the vacuum chamber is removed from the drum or carrier and treated with a suitable organic solvent to dissolve the release coating from the metal in a stripping process that leaves the metal flakes essentially release coat free.

Abstract: A process for making functional or decorative flakes or platelets economically and at high production rates comprises applying a multi-layer sandwich of vapor deposited metal and release coats in alternating layers to a rotating chilled drum or suitable carrier medium contained in a vapor deposition chamber. The alternating metallized layers are applied by vapor deposition and the intervening release layers are preferably solvent soluble thermoplastic polymeric materials applied by vapor deposition sources contained in the vapor deposition chamber. The multi-layer sandwich built up in the vacuum chamber is removed from the drum or carrier and treated with a suitable organic solvent to dissolve the release coating from the metal in a stripping process that leaves the metal flakes essentially release coat free.

Abstract: A process for making functional or decorative flakes or platelets economically and at high production rates comprises applying a multi-layer sandwich of vapor deposited metal and release coats in alternating layers to a rotating chilled drum or suitable carrier medium contained in a vapor deposition chamber. The alternating metallized layers are applied by vapor deposition and the intervening release layers are preferably solvent soluble thermoplastic polymeric materials applied by vapor deposition sources contained in the vapor deposition chamber. The multi-layer sandwich built up in the vacuum chamber is removed from the drum or carrier and treated with a suitable organic solvent to dissolve the release coating from the metal in a stripping process that leaves the metal flakes essentially release coat free.

Abstract: A process for making a protective and decorative surfacing film comprises extrusion coating a solventless polymeric material from an extruder die to form an optically clear first layer on a polyester carrier sheet traveling past the extruder die opening. The extrusion coated first layer is immediately cooled on the carrier sheet to harden it, followed by applying a pigmented second layer to the first layer. The composite paint coat is transferred to a reinforcing backing sheet, after which the carrier sheet is separated from the paint coat to expose the outer surface of the first layer as a high gloss surface with a high distinctness-of-image, providing a transparent protective outer coat for the pigmented second layer. The pigmented second layer can be solvent cast and dried or extruded and hardened as a separate coating on the first layer. The composite paint coat can be bonded to a coextruded size coat and semi-rigid plastic substrate panel to form a thermoformable laminate.

Abstract: A process for making functional or decorative flakes or platelets economically and at high production rates comprises applying a multi-layer sandwich of vapor deposited metal and release coats in alternating layers to a rotating chilled drum or suitable carrier medium contained in a vapor deposition chamber. The alternating metallized layers are applied by vapor deposition and the intervening release layers are preferably solvent soluble thermoplastic polymeric materials applied by vapor deposition sources contained in the vapor deposition chamber. The multi-layer sandwich built up in the vacuum chamber is removed from the drum or carrier and treated with a suitable organic solvent to dissolve the release coating from the metal in a stripping process that leaves the metal flakes essentially release coat free.

Abstract: A process for making a protective and decorative surfacing film comprises extrusion coating a solventless polymeric material from an extruder die to form an optically clear first layer on a polyester carrier sheet traveling past the extruder die opening. The extrusion coated first layer is immediately cooled on the carrier sheet to harden it, followed by applying a pigmented second layer to the first layer. The composite paint coat is transferred to a reinforcing backing sheet, after which the carrier sheet is separated from the paint coat to expose the outer surface of the first layer as a high gloss surface with a high distinctness-of-image, providing a transparent protective outer coat for the pigmented second layer. The pigmented second layer can be solvent cast and dried or extruded and hardened as a separate coating on the first layer. The composite paint coat can be bonded to a coextruded size coat and semi-rigid plastic substrate panel to form a thermoformable laminate.

Abstract: A process for making a protective and decorative surfacing film comprises extrusion coating a solventless polymeric material from an extruder die to form an optically clear first layer on a polyester carrier sheet traveling past the extruder die opening. The extrusion coated first layer is immediately cooled on the carrier sheet to harden it, followed by applying a pigmented second layer to the first layer. The composite paint coat is transferred to a reinforcing backing sheet, after which the carrier sheet is separated from the paint coat to expose the outer surface of the first layer as a high gloss surface with a high distinctness-of-image, providing a transparent protective outer coat for the pigmented second layer. The pigmented second layer can be solvent cast and dried or extruded and hardened as a separate coating on the first layer. The composite paint coat can be bonded to a coextruded size coat and semi-rigid plastic substrate panel to form a thermoformable laminate.

Abstract: A process for making functional or decorative flakes or platelets economically and at high production rates comprises applying a multi-layer sandwich of vapor deposited metal and release coats in alternating layers to a rotating chilled drum or suitable carrier medium contained in a vapor deposition chamber. The alternating metallized layers are applied by vapor deposition and the intervening release layers are preferably solvent soluble thermoplastic polymeric materials applied by vapor deposition sources contained in the vapor deposition chamber. The multi-layer sandwich built up in the vacuum chamber is removed from the drum or carrier and treated with a suitable organic solvent to dissolve the release coating from the metal in a stripping process that leaves the metal flakes essentially release coat free.

Abstract: A process for making a protective and decorative surfacing film comprises extrusion coating a solid polymeric material to form an optically clear first layer (10) on a smooth surface of a carrier sheet (12). The extrusion coated first layer is immediately cooled, followed by applying a pigmented second material (22) in thin film form. The composite paint coat is then transferred to a supportive backing, after which the carrier sheet is removed to expose the high gloss outer surface of the first layer. The second layer may be solvent cast, extrusion coated, or coextruded with the first layer.

Abstract: An exterior automotive quality paint coat is laminated to the surface of a plastic car body member of panel. A dry paint transfer film is first laminated to a relatively thin semi-rigid thermoformable resinous backing sheet. The backing sheet side of the resulting laminate is then laminated to a relatively thick thermoformable substrate sheet comprising the same or a compatible polymeric material. The two sheets are joined by extruding the thick substrate sheet and using the heat of extrusion to then laminate the thin backing sheet to the thicker extruded substrate sheet. The resulting thick sheet laminate is then thermoformed, preferably by first heating the laminate to a forming temperature, followed by vacuum forming the laminate to a three-dimensional shape of the finished automotive part, such as a facia, ready to put on a vehicle.

Abstract: A multi-layer sandwich of vapor deposited metal and release coats in alternating layers is applied to a drum or carrier in a vapor deposition chamber. The metallized layers are applied by vapor deposition. The release layers are solvent soluble thermoplastic or lightly crosslinked polymeric materials applied by vapor deposition in the chamber. The multi-layer sandwich is removed and treated with solvent to dissolve the release coating from the metal flakes. The release coat material can be a radiation curable, crosslinkable vapor deposited polymeric material of low crosslink density. A high energy radiation source crosslinks the release material to produce tack-free, solvent soluble release coat layers. The multi-layer vapor deposit can be built up on an endless belt passing from the chamber through a separate vacuum lock. Both chambers are at vacuum pressures below atmospheric while depositing the flake material.

Abstract: A process for making a protective and decorative surfacing film comprises extrusion coating a solventless polymeric material from an extruder die to form an optically clear first layer on a polyester carrier sheet traveling past the extruder die opening. The extrusion coated first layer is immediately cooled on the carrier sheet to harden it, followed by applying a pigmented second layer to the first layer. The composite paint coat is transferred to a reinforcing backing sheet, after which the carrier sheet is separated from the paint coat to expose the outer surface of the first layer as a high gloss surface with a high distinctness-of-image, providing a transparent protective outer coat for the pigmented second layer. The pigmented second layer can be solvent cast and dried or extruded and hardened as a separate coating on the first layer. The composite paint coat can be bonded to a coextruded size coat and semi-rigid plastic substrate panel to form a thermoformable laminate.

Abstract: A process for making high aspect ratio metal flakes comprises applying a multi-layer sandwich of vapor deposited metal and release coats in alternating layers to a rotating chilled drum or suitable carrier medium contained in a vapor deposition chamber. The alternating metallized layers are applied by vapor deposition and the intervening release layers are preferably solvent-soluble materials applied by suitable coating or vapor deposition sources contained in the vapor deposition chamber. The release coat materials can be a thermoplastic solvent-soluble polymer. The multi-layer sandwich built up in the vacuum chamber is removed from the drum or carrier and treated with a suitable solvent to dissolve the release coating from the metal in a stripping process that leaves the metal flakes essentially release coat free.

Abstract: A process for making a low-gloss exterior body panel or member includes forming a thermoplastically formable dry paint transfer film on a heat-resistant temporary carrier having a low-gloss microroughness. The dry paint transfer film has a polymeric outer clear coat layer and a polymeric base coat layer containing a dispersed pigment. The clear coat layer contains (a) uniformly dispersed filler particles in an amount below about five parts by weight of the total resin binder solids and (b) a dispersion of a fluorinated polymeric material in a solvent solution of an acrylic resin. The dispersion has an average particle size from about 20 to about 35 microns. The dry paint transfer film is laminated to a semi-rigid thermoplastically formable resinous backing sheet on a side opposite from the clear coat layer. A relatively thick substrate sheet is extruded from a thermoformable polymeric material. A paint-coated thick sheet laminate is formed by laminating the backing sheet to the extruded sheet.

Abstract: A process for making a protective and decorative surfacing film comprises extrusion coating a solid polymeric material to form an optically clear first layer (10) on a smooth surface of a carrier sheet (12). The extrusion coated first layer is immediately cooled, followed by applying a pigmented second material (22) in thin film form. The composite paint coat is then transferred to a supportive backing, after which the carrier sheet is removed to expose the high gloss outer surface of the first layer. The second layer may be solvent cast, extrusion coated, or coextruded with the first layer.

Abstract: A process for making high aspect ratio metal flakes economically and at high production rates comprises applying a multi-layer sandwich of vapor deposited metal and release coats in alternating layers to a rotating chilled drum or suitable carrier medium contained in a vapor deposition chamber. The alternating metallized layers are applied by vapor deposition and the intervening release layers are preferably solvent or water soluble materials applied by suitable coating or vapor deposition sources contained in the vapor deposition chamber. The release coat materials can be a thermoplastic solvent-soluble polymer, a water soluble inorganic salt, or a high boiling point dissolvable wax-like substance. The multi-layer sandwich built up in the vacuum chamber is removed from the drum or carrier and treated with a suitable solvent or water to dissolve the release coating from the metal in a stripping process that leaves the metal flakes essentially release coat free.

Abstract: An exterior automotive quality paint coat is laminated to the surface of a plastic car body member of panel. A dry paint transfer film is first laminated to a relatively thin semi-rigid thermoformable resinous backing sheet. The backing sheet side of the resulting laminate is then laminated to a relatively thick thermoformable substrate sheet comprising the same or a compatible polymeric material. The two sheets are joined by extruding the thick substrate sheet and using the heat of extrusion to then laminate the thin backing sheet to the thicker extruded substrate sheet. The resulting thick sheet laminate is then thermoformed, preferably by first heating the laminate to a forming temperature, followed by vacuum forming the laminate to a three-dimensional shape of the finished automotive part, such as a facia, ready to put on a vehicle.

Abstract: A process for making functional or decorative flakes or platelets economically and at high production rates comprises applying a multi-layer sandwich of vapor deposited metal and release coats in alternating layers to a rotating chilled drum or suitable carrier medium contained in a vapor deposition chamber. The alternating metallized layers are applied by vapor deposition and the intervening release layers are preferably solvent soluble thermoplastic polymeric materials applied by vapor deposition sources contained in the vapor deposition chamber. The multi-layer sandwich built up in the vacuum chamber is removed from the drum or carrier and treated with a suitable organic solvent to dissolve the release coating from the metal in a stripping process that leaves the metal flakes essentially release coat free.

Abstract: A process for making a protective and decorative surfacing film comprises extrusion coating a solventless polymeric material from an extruder die to form an optically clear first layer on a polyester carrier sheet traveling past the extruder die opening. The extrusion coated first layer is immediately cooled on the carrier sheet to harden it, followed by applying a pigmented second layer to the first layer. The composite paint coat is transferred to a reinforcing backing sheet, after which the carrier sheet is separated from the paint coat to expose the outer surface of the first layer as a high gloss surface with a high distinctness-of-image, providing a transparent protective outer coat for the pigmented second layer. The pigmented second layer can be solvent cast and dried or extruded and hardened as a separate coating on the first layer. The composite paint coat can be bonded to a coextruded size coat and semi-rigid plastic substrate panel to form a thermoformable laminate.

Abstract: A process for making a protective and decorative surfacing film comprises extrusion coating a solid polymeric material from an extruder die to form an optically clear first layer of uniform film thickness on a smooth surface of a carrier sheet traveling continuously past the extruder die opening. The extrusion coated first layer is immediately cooled on the carrier sheet to harden it, followed by applying a pigmented second layer in thin film form to the first layer to form a composite paint coat in which the first and second layers are bonded to each other. The composite paint coat is then transferred to a supportive backing sheet or substrate panel, after which the carrier sheet is separated from the paint coat, to expose the outer surface of the first layer as a high gloss surface with a high distinctness-of-image, providing a transparent protective outer coat for the underlying pigmented second layer.