Avery Dennison Corporation

Other

Frederick Young

Howard H Enlow

Keith Lawson Truog

John E Roys

William J Buehne

Russell J McCready

Scott W Huffer

John J Markey

John R Johnson

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. Techniques are disclosed for producing extruded clear films of exceedingly high optical clarity using a closed air flow transport and HEPA filtration system that removes airborne particles from the resin handling and extrusion process, thereby preventing micron-sized contaminants naturally present from many sources from entering the process and degrading ultimate film quality.

Extruded polymeric high transparency films

A process for making a protective and decorative surfacing film comprises extrusion coating a solid polymeric material to form an optically clear first layer ( ) on a smooth surface of a carrier sheet ( ). The extrusion coated first layer is immediately cooled, followed by applying a pigmented second material ( ) 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.

Extrusion coating process for making protective and decorative films

Extrusion coating process for making high transparency protective and decorative films

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. The pigmented second layer can be solvent cast and dried or extruded and hardened as a separate coating on the extrusion coated first layer. Alternatively, the second layer can be formed with the first layer as a coextrusion which is extrusion coated onto the smooth surface of the release coated carrier sheet that travels past the extruder die.

Extrusion process for protective coatings for outdoor siding panels and the like

A flexible decorative sheet for use in surfacing an automobile body panel includes a first polyester carrier sheet having a high gloss surface, a clear coat of a weatherable optically-clear polymer containing fluorocarbon resin and an acrylic resin coated on the surface of the first carrier sheet, a tie coat on the clear coat, and a color coat containing a chlorinated polymer with dispersed pigments cast on the tie coat and dried. A pressure-sensitive adhesive layer is formed on a second polyester carrier sheet and then laminated to the exposed face of the color coat to form a pressure-sensitive, adhesive-backed composite paint coat between the outer carrier sheets which form protective removable backing sheets for the resulting laminate. The decorative sheet is applied to a substrate panel by pressure-sensitive adhesive bonding techniques, with the clear coat serving as a glossy, weatherable protective outer layer for the underlying color coat. The PVC-containing color coat enhances room temperature elongation of the finished film to enable application of the laminate to three-dimensionally contoured surfaces. The resulting paint finish has a defect-free, weatherable and durable outer surface with high gloss and high distinctness of image, meeting requirements for exterior automotive use.

Exterior automotive laminate with pressure-sensitive adhesive

A process for making a thermoformable conductive plastic laminate for use in making plastic parts adapted for electrostatic spray painting of a uniform high quality paint finish includes forming a matte release coated casting sheet, casting an electrically conductive polymer in thin film form on the casting sheet, drying to form a conductive primer coat, and transfer-laminating the conductive coating to a thin, thermoformable plastic face sheet. The matte release coat has a fine particulate filler that transfers a micro-roughened matte surface to the conductive primer coat. The conductive primer includes a polyester resin containing a fine particulate conductive material such as carbon black and, preferably, an anti-blocking agent such as fumed silica. The primer coated face sheet can be thermoformed and bonded to a underlying plastic substrate panel. The conductive primer has sufficient elongation and maintains uniform electrical surface conductivity and film thickness throughout the transfer-laminating, thermoforming and substrate panel-cladding process. The uniform surface resistivity of the conductive primer film is sufficient to permit electrostatic spray painting of the finished contoured panel and in one embodiment produces a Class 'A' quality exterior automotive paint finish on the resulting panel.

Thermoformable conductive laminate and process

A process for making a thermoformable conductive plastic laminate for use in making plastic parts adapted for electrostatic spray painting of a uniform high quality paint finish includes forming a matte release coated casting sheet, casting an electrically conductive polymer in thin film form on the casting sheet, drying to form a conductive primer coat, and transfer-laminating the conductive coating to a thin, thermoformable plastic face sheet. The matte release coat has a fine particulate filler that transfers a micro-toughened matte surface to the conductive primer coat. The conductive primer includes a polyester resin containing a fine particulate conductive material such as carbon black and, preferably, an anti-blocking agent such as fumed silica. The primer coated face sheet can be thermoformed and bonded to a underlying plastic substrate panel. The conductive primer has sufficient elongation and maintains uniform electrical surface conductivity and film thickness throughout the transfer-laminating, thermoforming and substrate panel-cladding process. The uniform surface resistivity of the conductive primer film is sufficient to permit electrostatic spray painting of the finished contoured panel and in one embodiment produces a Class 'A' quality exterior automotive paint finish on the resulting panel.

Exterior automotive laminate with pressure sensitive adhesive

Specific gravity metal separator

A material separator that magnetically separates the desired material from a slurry as the slurry travels along one or more passageways between a hopper and a discharge chute. Riffle lines can also be incorporated in such passageways to increase the separation capabilities of the material separator. Additionally, as the need arises, more or fewer passageways can be added or removed to adjust the collection efficiency of the material separator.

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Schererville, IN, United States of America

Frederick Young