Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1998-02-06
2001-03-27
Ball, Michael W. (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S244110, C156S244190, C156S280000, C156S289000, C427S154000
Reexamination Certificate
active
06206998
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to simplified methods for making thermoplastic formable plastic sheets joined with decorative colorants deposited thereon. This product is capable of being formed into body panels or trim components such as for automotive vehicle bodies as well as for other suitable purposes.
BACKGROUND OF THE INVENTION
Current practice in the manufacture of thermoplastic formable plastic sheets laminated with decorative films involves numerous steps. A film supplier first builds a paint film by providing a carrier layer of flexible but nonformable plastic film,. such as polyester, typically a “Mylar” 200A polyethylene terephthalate (PET). On the carrier layer, one or two coats of clear coat finish are formed on which a layer of color coat paint film is applied. The clear and color coats may be sprayed, calendared or otherwise applied.
Because the resulting multi-layer film is thin and difficult to handle, it is then laminated to a thin wall thermoplastic polyolefin (TPO) sheet, typically about 6-20 mils thick but thicknesses up to 60 mils can be used. The laminated product is then shipped to an extruder to have the thin wall sheet side of the product laminated to a thick wall TPO sheet about 0.065-0.300 inches thick. This may be accomplished as part of the extrusion process. In some cases, the nonformable carrier is removed prior to lamination by peeling it off the thin wall laminate, because if left thereon, it may interfere with the lamination process. The result is the desired thermoplastic formable laminated decorative sheet. In other cases, the carrier layer is left on the laminated sheet to protect the clear coat finish from damage in handling and is only removed prior to forming the decorative sheet into a final or intermediate molded product.
SUMMARY OF THE INVENTION
The present invention provides several improved and simpler methods for making decorative colored structural sheets that are formable at elevated temperatures into decorative structural and trim components, such as vehicle bodies or panels. In general, the invention is characterized by the steps of:
providing a thermoplastic formable plastic sheet;
applying, on a surface of said plastic sheet, an unsolidified colorant capable of serving as a decorative first film.
An additional optional step includes applying, on said first film, a second film of thermoformable clear coat bonded to said first film and forming a high quality outer surface covering the decorative first film.
The decorative first film may be composed of any form of unsolidified colorant such a dry powder or wet. The unsolidified film may be sprayed, calendared or otherwise applied. It may include a bonding agent which, upon curing of the unsolidified coating, causes the resulting dry film to adhere to the plastic panel.
The film (optional) of clear coat material may be applied in liquified or powdered form and cured as is the first film, or it may comprise a solidified dry film that is laminated onto the first film in the dry condition in accordance with known methods.
The depositing of decorative film and/or the second film may be continuous, non-continuous, depict indicia such as alphanumeric characters or pictures.
The formable plastic sheet is preferably made as a continuous extrusion, although any other form of processing may be utilized. The first and second films may be applied directly to the continuously extruded sheet, which is thereafter cut into desired lengths for processing or shipping. Alternatively, the extruded sheet may be cut into separate sheets and the films applied to the separated sheets to form the laminated decorative formable sheets of the invention.
If the decorative sheets are to be stored, shipped or handled extensively prior to placement in a forming apparatus for heating and forming into structural or trim components, it may be preferable to cover the laminated decorative surface with a protective layer of film to protect the surface against damage before forming. If a thermoformable protective layer is used, it may be left on the formed part to protect the finish until a later time, such as when the product is applied to a vehicle and even until the vehicle is delivered to an ultimate customer.
If the laminated sheet is to be compression formed, a second protective layer may be applied to protect the thermoformable first protective layer against damage prior to the forming operation as is disclosed in a copending commonly assigned patent application. This method prevents damage done to the first layer from penetrating into the decorative surface during the compression forming operation.
The disclosed method also contemplates an extruded colorant and an extruded second film.
These and other features and advantages of the invention will be more fully understood from the following description of certain exemplary embodiments of the invention taken together with the accompanying drawings.
REFERENCES:
patent: 3620872 (1971-11-01), Backwell
patent: 3645822 (1972-02-01), Widiger et al.
patent: 4329196 (1982-05-01), Rawlinson
patent: 4330352 (1982-05-01), Grimes et al.
patent: 4423106 (1983-12-01), Mahn
patent: 4824506 (1989-04-01), Hoerner et al.
patent: 4913760 (1990-04-01), Benson et al.
patent: 5286528 (1994-02-01), Reafler
patent: 5395659 (1995-03-01), Graf et al.
patent: 5538576 (1996-07-01), Knop et al.
Android Industries of Michigan LLC
Ball Michael W.
Piazza Gladys
Rader & Fishman & Grauer, PLLC
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