Gm Global Technolgoy Operations, Inc.

Delphi Technologies, Inc.

William T Short

Howard W Cox

Charles C Mentzer

Robert Augustine Ottaviani

Donald J Hart

Rebecca S Hoerner

A fuel permeation barrier fuel tank for a vehicle includes a tank shell having a wall formed from a plurality of layers. The layers include at least an inner layer, an outer layer, a fuel permeation barrier layer disposed between the inner layer and the outer layer, and a thermoformable layer disposed adjacent the outer layer to improve permeation resistance and protection against radiant environmental heating of the fuel tank.

Fuel permeation barrier fuel tank

A fuel permeation barrier fuel tank for a vehicle includes a tank shell having a wall formed from a plurality of layers. The layers include at least an inner layer, an outer layer and a fuel permeation barrier layer disposed between the inner layer and the outer layer, and a thermoformable layer disposed between the fuel permeation barrier layer and the outer layer to improve permeation resistance of the fuel tank.

A vapor removal fuel containment fuel tank for a vehicle includes a tank shell having a wall formed from a primary fuel containment layer. The fuel tank also includes a secondary fuel containment layer disposed adjacent the primary fuel containment layer to contain fuel therein. The fuel tank further includes a vapor removal system extending through the primary fuel containment layer to allow fuel vapors that build up between the primary fuel containment layer and secondary fuel containment layer to be removed from the fuel tank.

Vapor removal fuel containment fuel tank

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.

Thermoformable multihued laminate films and processes

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.

Process of making thermoformable laminate films and processes

Process for thermoforming multihued laminate films

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.

Article covered with painted carrier films

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.

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.

Method of applying painted carrier films to automobile body parts

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.

Process for protecting thermoformed films

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

Method of applying carrier films prepainted with metallic paint to

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.

Sag control of high solid polyurethane clearcoats by urea

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.

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.

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Southfield, MI, United States of America

William T Short