Abstract: A multi-layer laminate having a textured surface comprises a thin, flexible, thermoformable polymeric base layer, and a layer of spaced part segments of an ink material screen printed in a pattern on a surface of the polymeric base material. The ink material comprises a UV curable screen printing ink which contains a resinous binder, a hardener, and a fine particulate filler. The ink is pressed through a screen having an emulsion with a thickness from about 40 to 50 microns. The ink segments are dried on the base layer by UV curing to a height and a hardness sufficient to form a heat stable textured surface adhered to the base layer. In one embodiment, the printed ink layer has a print height from about 25 to about 50 microns and resists deformation from subsequent thermoforming and/or injection molding. The ink segments meet automotive hardness and abrasion specification requirements.

Abstract: A thermoformable decorative automotive laminate includes a flexible free film comprising a transparent UV light-stabilized cellulosic outer film, an optional primer, ink layers, and an opaque layer. The cellulosic outer film may include cellulose acetate butyrate and/or cellulose acetate propionate. The cellulosic film may he laminated to a polymeric sheet or film and thermo-formed to a three dimensional shape while maintaining a high gloss and DOI along with durability properties suitable for interior or exterior automotive use.

Abstract: A multi-layer laminate having a textured surface comprises a thin, flexible, thermoformable polymeric base layer, and a layer of spaced part segments of an ink material screen printed in a pattern on a surface of the polymeric base material. The ink material comprises a UV curable screen printing ink which contains a resinous binder, a hardener, and a fine particulate filler. The ink is pressed through a screen, producing ink segments which are dried on the base layer by UV curing to a height and a hardness sufficient to form a heat stable textured surface adhered to the base layer, In one embodiment, the printed ink layer has a print height from about 25 to about 85 microns and resists deformation from subsequent thermoforming and/or injection molding. The ink segments meet OEM automotive hardness and abrasion specification requirements.

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 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 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 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 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: 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 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.

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.

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 of 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 fascia, ready to put on a vehicle.

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.