Avery Dennison Corporation

E.i. Dupont De Nemours and Company

Avery Dennison Coporation

Patrick Leon Spain

Keith Lawson Truog

Frank Rohrbacher

Roger A Fahlsing

Jeffery W Johnson

Paul L Adesko

An automotive quality paint coat is laminated to the exterior surface of a molded plastic car body member or panel. In one embodiment, the paint coat includes an exterior clear coat above a color coat. During processing, the clear coat and color coat are each coated on a temporary flexible casting sheet and dried. A high gloss surface is transferred to the clear coat from the casting sheet. The paint coat is then transferred from the casting sheet to a thin, semi-flexible thermoformable plastic backing sheet by dry paint transfer-laminating techniques. The resulting laminate is thermoformed into a complex three-dimensional shape of the car body member or panel. The preformed laminate is then bonded to an underlying plastic substrate material, by injection-cladding techniques, for example, to form the finished article. The paint coat has sufficient elongation to retain exterior automotive appearance and durability properties during thermoforming without deglossing. The backing sheet absorbs defects in the substrate material so the paint coat retains its appearance and durability properties during the injection-cladding step. The finished article comprises a high gloss, defect-free paint coat on the exterior of a molded plastic car body member or panel. Solution-form polyvinylidene fluoride/acrylic paint systems have remarkably high combined gloss and distinctiveness-of-image levels, together with durability properties required for exterior automotive use.

Dry paint transfer process for making deep-draw high doi automotive body panels

Dry paint transfer-lamination process for making high DOI automotive body panels

An automotive quality paint coat () is laminated to the exterior surface of a molded plastic car body member or panel (). In one embodiment, the paint coat () includes an exterior clear coat () above a color coat (). During processing, the clear coat () and color coat () are each coated on a temporary flexible casting sheet () and dried. A high gloss surface is transferred to the clear coat () from the casting sheet (). The paint coat () is then transferred from the casting sheet () to a thin, semi-flexible thermoformable plastic backing sheet () by dry paint transfer-laminating techniques. The resulting laminate () is thermoformed into a complex three-dimensional shape of the car body member or panel. The preformed laminate () is then bonded to an underlying plastic substrate material, by injection-cladding techniques, for example, to form the finished article. The paint coat () has sufficient elongation to retain exterior automotive appearance and durability properties during thermoforming without deglossing. The backing sheet () absorbs defects in the substrate material so the paint coat retains its appearance and durability properties during the injection-cladding step. The finished article comprises a high gloss, defect-free paint coat on the exterior of a molded plastic car body member or panel. Solution-form polyvinylidene fluoride/acrylic paint systems have remarkably high combined gloss and distinctiveness-of-image levels, together with durability properties required for exterior automotive use.

Dry paint transfer process and product

An automotive quality paint coat ( ) is laminated to the exterior surface of a molded plastic car body member or panel ( ). In one embodiment, the paint coat ( ) includes an exterior clear coat ( ) above a color coat ( ). During processing, the clear coat ( ) and color coat ( ) are each coated on a temporary flexible casting sheet ) and dried. A high gloss surface is transferred to the clear coat ( ) from the casting sheet ( ). The paint coat ( ) is then transferred from the casting sheet ( ) to a thin, semi-flexible thermoformable plastic backing sheet ( ) by dry paint transfer-laminating techniques. The resulting laminate ( ) is thermoformed into a complex three-dimensional shape of the car body member or panel. The preformed laminate ( ) is then bonded to an underlying plastic substrate material, by injection-cladding techniques, for example, to form the finished article. The paint coat ( ) has sufficient elongation to retain exterior automotive appearance and durability properties during thermoforming without deglossing. The backing sheet ( ) absorbs defects in the substrate material so the paint coat retains its appearance and durability properties during the injection-cladding step. The finished article comprises a high gloss, defect-free paint coat on the exterior of a molded plastic car body member or panel. Solution-form polyvinylidene fluoride/acrylic paint systems have remarkably high combined gloss and distinctiveness-of-image levels, together with durability properties required for exterior automotive use.

An automotive quality paint coat ( ) is laminated to the exterior surface of a molded plastic car body member or panel ( ). In one embodiment, the paint coat ( ) includes an exterior clear coat ( ) above a color coat ( ). During processing, the clear coat ( ) and color coat ( ) are each coated on a temporary flexible casting sheet ( ) and dried. A high gloss surface is transferred to the clear coat ( ) from the casting sheet ( ). The paint coat ( ) is then transferred from the casting sheet ( ) to a thin, semi-flexible thermoformable plastic backing sheet ( ) by dry paint transfer-laminating techniques. The resulting laminate ( ) is thermoformed into a complex three-dimensional shape of the car body member or panel. The preformed laminate ( ) is then bonded to an underlying plastic substrate material, by injection-cladding techniques, for example, to form the finished article. The paint coat ( ) has sufficient elongation to retain exterior automotive appearance and durability properties during thermoforming without deglossing. The backing sheet ( ) absorbs defects in the substrate material so the paint coat retains its appearance and durability properties during the injection-cladding step. The finished article comprises a high gloss, defect-free paint coat on the exterior of a molded plastic car body member or panel. Solution-form polyvinylidene fluoride/acrylic paint systems have remarkably high combined gloss and distinctiveness-of-image levels, together with durability properties required for exterior automotive use.

Dry paint transfer lamination process for making high DOI automotive body panels

An automotive quality paint coat ( ) is laminated to the exterior surface of a molded plastic car body member or panel ( ). In one embodiment, the paint coat ( ) includes an exterior clear coat ( ) above a color coat ( ). During processing, the clear coat ( ) and color coat ( ) are each coated on a temporary flexible casting sheet ( ) and dried. A high gloss surface is transferred to the clear coat ( ) from the casting sheet ( ). The paint coat ( ) is then transferred from the casting sheet ( ) to a thin, semi-flexible thermoformable plastic backing sheet ( ) by dry paint transfer-laminating techniques. The resulting laminate ( ) is thermoformed into a complex three-dimensional shape of the car body member or panel. The preformed laminate ( ) is then bonded to an underlying plastic substrate material, by injection-clading techniques, for example, to form the finished article. The paint coat ( ) has sufficient elongation to retain exteriot automotive appearance and durability properties during thermoforming without deglossing. The backing sheet ( ) absorbs defects in the substrate material so the paint coat retains its appearance and durability properties during the injection-cladding step. The finished article comprises a high gloss, defect-free paint coat on the exterior of a molded plastic car body member or panel. Solution-form polyvinylidene fluoride/acrylic paint systems have remarkably high combined gloss and distinctiveness-of-image levels, together with durability properties required for exterior automotive use.

Dry paint transfer process for making deep draw high DOI automotive body panels

An automotive quality paint coat is laminated to the exterior surface of a molded plastic car body panel. In one embodiment, the paint coat includes an exterior clear coat above a color coat. The clear coat and color coat are each coated on a temporary flexible casting sheet and dried. A high gloss surface is transferred to the clear coat from the casting sheet. The paint coat is then transferred from the casting sheet to a thin, semi-flexible thermoformable plastic backing sheet by dry paint transfer-laminating techniques. The resulting laminate is thermoformed into a complex three-dimensional shape of the car body panel. The preformed laminate is then bonded to a plastic substrate material by injection-cladding techniques to form the finished article. The paint coat has sufficient elongation to retain exterior automotive appearance and durability properties during thermoforming without deglossing. The backing sheet absorbs defects in the substrate material so the paint coat retains its appearance and durability properties. The finished article comprises a high gloss, defect-free paint coat on the exterior of a molded plastic car body panel.

A shaped exterior automotive body part having a contoured decorative outer surface, comprising a supporting substrate sheet and a decorative transfer film bonded to one side of said substrate sheet and conforming to said contoured surface, said decorative transfer film having a clear coat/color coat exterior automotive paint film comprising a flexible outer clear coat layer having a glossy, smooth outer surface, the clear coat layer formed of an optically clear, thermoplastic and thermoformable weatherable polymeric material, and a pigmented color coat of automotive quality paint adhered to an inner surface of said outer clear coat layer, the color coat formed of a thermoplastic and thermoformable polymeric material with pigments distributed therein to provide a layer of color visible to the outer surface of the automotive body part; said supporting substrate sheet comprising a continuous and self-supporting thermoformable polymeric material having contoured surface regions formed by having thermoformed the composite of the substrate sheet and the clear coat/color coat paint film to a finished deep-draw contoured shape of the body part, the decorative transfer film having regions thereof which have been subjected to elongation greater than about 50% during such thermoforming for conforming to said contoured regions of the substrate sheet to provide the outer component of a finished glossy contoured body part having an exterior automotive quality paint finish, including a distinctness-of-image value of at least 60 quantified by instrument measurement of said value.

Dry paint transfer-laminated body panels having deep-draw high DOI

An automotive quality paint coat is laminated to the exterior surface of a molded plastic car body panel. In one embodiment, the paint coat includes an exterior clear coat above a color coat. The clear coat and color coat are each coated on a temporary flexible casting sheet and dried. A high gloss surface is transferred to the clear coat from the casting sheet. The paint coat is then transferred from the casting sheet to a thin, semi-flexible thermoformable plastic backing sheet by dry paint transfer-laminating techniques. The resulting laminate is thermoformed into a complex three-dimensional shape of the car body panel. The preformed laminate is then bonded to a plastic substrate material by injection-cladding techniques to form the finished article. The paint coat has sufficient elongation to retain exterior automotive appearance and durability properties during thermoforming without deglossing. The backing sheet absorbs defects in the substrate material so the paint coat retains its appearance and durability properties. The finished article comprises a high gloss, defect-free paint coat on the exterior of a molded plastic car body panel. Solution-form polyvinylidene fluoride/acrylic paint systems have remarkably high combined gloss and distinctiveness-of-image levels and durability properties.

Dry paint transfer process for making high DOI automotive body panels

Dry paint transfer product having high DOI automotive paint coat

A process for making plastic siding panels, such as outdoor weatherable vinyl panels with an embossed wood grain pattern, comprises extruding a vinyl sheet, and overlaying on the extruded sheet a flexible carrier sheet having coated thereon (a) matte release layer bonded to the carrier sheet, and (b) decorative coating on the matte release layer facing toward the extruded plastic sheet. An embossing roll applies pressure at elevated temperatures to transfer the decorative coating from the matte release layer and bond it to the extruded sheet, while the embossing roll embosses a three-dimensional impression pattern in the laminate transferred to the extruded sheet. The carrier sheet and its matte release layer are then released from the laminate transferred to the vinyl sheet. The matte release layer transfers a low 75.degree. gloss level, preferably in the range of 8 to 12 gloss units, while enabling free release of the carrier from the embossed low gloss surface at elevated temperatures. In one embodiment, a multi-layer wood grain printed acrylic/polyvinylidene fluoride blended decorative coating is simultaneously transferred to a vinyl extrusion and embossed with a three dimensional wood grain texture. A color coat behind wood grain print coats contains pigment at a level that protects the vinyl substrate from UV deterioration. The matte release layer contains a suspended wax which enhances forming the low gloss surface while improving release of the matte release layer from the transferred laminate. A silicone resin in the matte release coat combines with the wax to further enhance release properties.

Process for manufacturing plastic siding panels with outdoor weatherable

Plastic siding panels with outdoor weatherable embossed surfaces

A process for making plastic siding panels, such as outdoor weatherable vinyl panels with an embossed wood grain pattern, comprises extruding a vinyl sheet, and overlaying on the extruded sheet a flexible carrier sheet having coated thereon (a) matte release layer bonded to the carrier sheet, and (b) decorative coating on the matte release layer facing toward the extruded plastic sheet. An embossing roll applies pressure at elevated temperatures to transfer the decorative coating from the matte release layer and bond it to the extruded sheet, while the embossing roll embosses a three-dimensional impression pattern in the laminate transferred to the extruded sheet. The carrier sheet and its matte release layer are then released from the laminate transferred to the vinyl sheet. The matte release layer transfers a low 75.degree. gloss level, preferably in the range of 8 to 12 gloss units, while enabling free release of the carrier from the embossed low gloss surface at elevated temperatures. In one embodiment, a multi-layer wood grain printed acrylic/polyvinylidene fluoride blended decorative coating is simultaneously transferred to a vinyl extrusion and embossed with a three dimensional wood grain texture. A color coat behind wood grain print coats contains pigment at a level that protects the vinyl substrate from UV deterioration. The matte release layer contains a suspended wax which enhances forming the low gloss surface while improving release of the matte release layer from the transferred laminate.

A process for forming a composite that is useful as an exterior vehicle part in which a layer of a coating composition is applied to a flexible smooth glossy polymeric carrier sheet and dried and laminated under heat and pressure to a flexible polymeric substrate to form a laminate, the carrier sheet is removed and the laminate is thermoformed into a three dimensional structure and a rigid thermoformable plastic is adhered to the thermoformed laminate to form the composite; the coating compsition used in the process that forms the exterior finish on the composite has a film forming binder which is in an organic liquid carrier is of a polyesterurethane and a multifunctional crosslinking agent of an epoxy compound or an organic polyisocyanate; wherein

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Lowell, IN, United States of America

Patrick Leon Spain