Patent ID: 6284183
Filing Date: 2001-09-04
Classification: B29C,B29K,B29L,B32B,Y10T

Abstract:
A process for making an exterior automotive quality body panel member from a preformed dry paint transfer laminate comprising an exterior automotive quality dry paint transfer film applied to a relatively thin semi-rigid thermoformable polymeric backing sheet, comprising the steps ofextruding a relatively thick sheet comprising a thermoformable polymeric material;forming a paint-coated thick sheet laminate by laminating the backing sheet side of the preformed dry paint laminate to the extruded sheet, using the heat of extrusion to heat bond the backing sheet and extruded sheet together to form an integral substrate sheet which is thermoformable to a three-dimensional shape with the dry paint film bonded to its surface, the backing sheet and extruded sheet comprising compatible polymeric materials to promote the bond between them, the extruded sheet having a thickness at least twice the thickness of the backing sheet, and in which the polymeric material of the extruded substrate sheet has a substantially higher filler content than the backing sheet material;applying heat to the resulting thick sheet laminate to raise the substrate sheet to a forming temperature, including applying heat to the thick sheet laminate by a temperature gradient in which the amount of heat applied to the substrate side of the laminate is greater than the amount of heat applied to the paint film side in raising the temperature of the laminate to its forming temperature; andforming the laminate to a three-dimensional shape to produce a finished exterior automotive quality body panel or member,in which the dry paint transfer film comprises an exterior automotive base coat/clear coat paint film and in which the distinctness-of-image of the finished thermoformed panel is at least 60.