Abstract: Thermoformable laminate films with a decorative feature include a polymer carrier film, a paint layer and a protective clearcoat and the clearcoat and paint layer have a preconfiguration which causes desired decorative features following deformation of the laminate by a thermoforming process. The laminated film has a paint coat of a desired hue and the protective clearcoat has a variable thickness selected to produce a two tone appearance in a finished molded product. The process of manufacture includes the steps of painting a polymeric support or carrier film and laminating the painted carrier film by process steps which will control the finished appearance of the laminate when applied to an underlying relatively rigid substrate or body part.

Abstract: Thermoformable laminate films with a decorative feature include a polymer carrier film, a paint layer and an optional protective clearcoat and the clearcoat and paint layer have a preconfiguration which produces uniform decorative color appearances following deformation of the laminate by a thermoforming process. To accomplish such results, the laminated film has a carrier film prestretched to orient pigment flakes in the paint layer prior to molding, thereby to reduce strain levels required to mold the laminate with an acceptable surface appearance. The process of manufacture includes the steps of painting a polymeric support or carrier film and prestretching the painted carrier film to control the color hue appearance of the laminate as applied to an underlying relatively rigid substrate or body part.

Abstract: Thermoformable laminate films with a decorative feature include a polymer carrier film, a paint layer and a protective clearcoat and the clearcoat and paint layer have a preconfiguration which causes desired decorative features following deformation of the laminate by a thermoforming process. The laminated film has a paint coat of a desired hue and the protective clearcoat has a variable thickness selected to produce a two tone appearance in a finished molded product. The process of manufacture includes the steps of painting a polymeric support or carrier film and laminating the painted carrier film by process steps which will control the finished appearance of the laminate when applied to an underlying relatively rigid substrate or body part.

Abstract: A article made by the method of applying a prepainted carrier film to an automobile body part in a vacuum thermoforming process. The article comprises a prepainted carrier film surface layer, an adhesive layer, and a rigid substrate layer. The prepainted carrier film has a top surface painted by a color coat formulation containing flakes and then coated with a layer of clear coat having a thickness of no less than 15 microns. The prepainted carrier film is heated and stretched in a vacuum thermoforming process and then assembled to a substrate for an automobile body part by adhesive means. The clear coat layer retains substantially the same gloss and color appearance of the stretched prepainted carrier film as prior to such stretch.

Abstract: A method of applying a prepainted carrier film to an automobile body part in a vacuum thermoforming process. The prepainted carrier film has a top surface painted by a color coat formulation not containing any flakes and then coated with a layer of clear coat having a thickness of no less than 10 microns. The prepainted carrier film is heated and stretched in a vacuum thermoforming process and then assembled to a substrate for an automobile body part by adhesive means. The clear coat layer retains substantially the same gloss and color appearance of the stretched prepainted carrier film as prior to the such stretch.

Abstract: A method of applying a prepainted carrier film to an automobile body part in a vacuum thermoforming process. The prepainted carrier film has a top surface painted by a color coat formulation containing flakes and then coated with a layer of clear coat having a thickness of no less than 15 microns. The prepainted carrier film is heated and stretched in a vacuum thermoforming process and then assembled to a substrate for an automobile body part by adhesive means. The clear coat layer retains substantially the same gloss and color appearance of the stretched prepainted carrier film as prior to such stretch.

Abstract: A method of applying a prepainted carrier film to an automobile body part in a vacuum thermoforming process. The prepainted carrier film has a top surface painted by a color coat formulation not containing any flakes and then coated with a layer of clear coat having a thickness of no less than 10 microns. The prepainted carrier film is heated and stretched in a vacuum thermoforming process and then assembled to a substrate for an automobile body part by adhesive means. The clear coat layer retains substantially the same gloss and color appearance of the stretched prepainted carrier film as prior to the such stretch.

Abstract: A process for thermoforming a decorative glossy film to a relatively rigid substrate includes the steps of: providing a carrier film having a heat absorption limit or a plurality of heat absorption limits above which decorative degradation occurs during direct exposure to heat sources of thermoforming apparatus; thermally protecting the surface of the carrier film with a layer of material with a heat absorption rate which will shield the carrier film against excessive heat buildup while softening the carrier film for drawing against a substrate; drawing the carrier film and the protective layer thereon into bonded engagement with the relatively rigid substrate; and thereafter removing the thermal protection layer without degrading the appearance of the decorative carrier film.

Abstract: A method of applying a carrier film prepainted with metallic paint containing metal flakes to an automobile body panel in a vacuum forming process.

Abstract: Novel, high solids urethane clearcoat compositions having improved flow characteristics by the incorporation of a flow control system composed of urea thixotrope/acrylic microgel additives. The urea thixotrope constituent is prepared by reacting a polyether polyol with a stoichiometric excess of a saturated cyclic aliphatic polyisocyanate to produce isocyanate-terminated prepolymers. These prepolymers are then modified by reaction with an ethanolamine to form urea end-capped thixotropes which are compatible in structure with any urethane clearcoat system. A combination of one of these urea thixotropes and a polymethyl methacrylate microgel of fine particle size is used effectively to reduce sagging of high solids urethane clearcoat systems. In fact, the combination of the two components produces a synergistic effect which is greater than that expected from any one of the components in the flow control system.

Abstract: Novel, high solids urethane clearcoat compositions having improved flow characteristics by the incorporation of a flow control system composed of urea thixotrope/silica additives. The urea thixotrope constituent is prepared by reacting a polyether polyol with a stoichiometric excess of a saturated cyclic aliphatic polyisocyanate to produce isocyanate-terminated prepolymers. These prepolymers are then modified by reaction with an ethanolamine to form urea endcapped thixotropes which are compatible in structure with any urethane clearcoat system. A combination of one of these urea thixotropes and a finely divided transparent silica is used effectively to reduce sagging of high solids urethane clearcoat systems. In fact, the combination of the two components produces a synergistic effect which is greater than that expected from any one of the components in the flow control system.

Abstract: Urethane-urea flow control agents are synthesized by a two-step process. First, an isocyanate-terminated urethane prepolymer is prepared by reacting a polyether polyol with a stoichiometric excess of a saturated cyclic aliphatic polyisocyanate. These isocyanate-terminated prepolymers are then modified by reaction with an ethanolamine to form urea endcapped flow control agents having number average molecular weight of between 1000 and 4000. These urea endcapped flow control agents can be blended with any urethane paint system and be compatible in structure. They have shown specifically superior compatibility with melamine cured high solids urethane paint systems. When blended with pigmented urethane paint at relatively small amounts, these flow control agents greatly reduce sagging while maintaining excellent leveling and viscosity properties of the paint.

Abstract: Novel, low viscosity, high solids paint compositions have been created which provide durable, high gloss surface finishes when they are applied to and cured over suitable substrates. The paints are based on urethane binder resins formed by initially reacting a hindered piperidinol ultraviolet stabilizer with a stoichiometric excess of aliphatic polyisocyanate. This reaction product is in turn reacted with a stoichiometric excess of polyether polyols. The paint compositions are cured by crosslinking the urethane binder resins at the unreacted functional hydroxyl groups of the polyol constituents by means of acid catalyzed, melamine formaldehyde crosslinking agents. Cure can generally be fully accomplished in a short time at temperatures below about 250.degree. F. The cured paint has piperidine groups chemically incorporated within its molecular structure to effectively inhibit the degradation of the urethane linkages and the loss of gloss by ultraviolet radiation.

Abstract: In a preferred embodiment, an improved moisture curing urethane resin that is durable in the presence of moisture and sunlight is formed by reacting an excess of a suitable aliphatic isocyanate with a suitable mixture of organic triols and diols and a hindered piperidine type stabilizer, e.g., bis(2,2,6,6 tetramethyl piperidinyl-4) sebacate in the presence of an organotin urethane forming catalyst such as dibutyltin dilaurate. This resin mixture product may be formulated with pigments, solvents and the like to form a topcoat paint that, upon application to a substrate, is curable under conditions of high relative humidity but relatively low temperatures (e.g., about 90.degree. C.). The cured paint has excellent gloss stability due to the chemical incorporation of the stabilizer segments throughout the binder resin molecules.

Abstract: In a preferred embodiment, an improved high solids polyurethane paint composition contains metallic flake pigment and a binder comprising a particular isocyanate-terminated polyether-urethane resin. The resin is formed by reacting an excess of a suitable aliphatic diisocyanate with a suitable mixture of polyoxypropylene diols and triols and a hindered piperidine type UV stabilizer in the presence of an organotin catalyst. The product urethane resin having the stabilizer reacted into its molecular structure is formulated with color producing pigments, metallic flakes and a suitable solvent to produce a composition having a nonvolatiles content of 60 to 70 weight percent. The composition is spray applied to a substrate and moisture cured to provide a decorative topcoat wherein the flakes lie at varying depths and are oriented substantially parallel to the topcoat surface.

Abstract: In accordance with a preferred embodiment of this invention, an active agent, such as a catalyst or a cocatalyst, is encapsulated in a dual-walled microcapsule. Both walls of the microcapsule are polymerization reaction products and both are formed in one basic process. The active agent is initially dissolved in a slowly polymerizing liquid monomer mixture such as a solution of toluene diisocyanate and a polyoxyalkylene polyol. The "monomer solvent" and the active agent combination is selected so that the active agent is nonreactive but soluble in the liquid monomer and insoluble in the polymer formed therefrom. However, before the active agent precipitates, the solution is dispersed in a nonreactive medium and the outer polymeric wall is formed by vigorously stirring the dispersion and then adding a reactive polyfunctional monomer.