Patent Publication Number: US-2002009598-A1

Title: Scratch resistant color match laminate

Description:
FIELD OF THE INVENTION  
       [0001] The present invention relates in general to laminated products and methods of making the same, and in particular to flexible, thermoformable laminated sheet materials that can be attached to various substrates, including exterior automotive body panels and trim parts, as a protective and decorative covering, and methods of making the same.  
       BACKGROUND OF THE INVENTION  
       [0002] The advent of exterior automotive body panels and trim parts comprised of thermoplastic materials has enabled manufacturers to reduce assembly costs, production time, and fuel consumption rates of modern automobiles, as compared to older automobile models that incorporated large amounts of sheet metal into their designs. However, the use of these thermoplastic exterior automotive body panels and trim parts also required manufacturers to employ painting techniques that produced panels and parts that have acceptable physical properties that are important to consumers, such as gloss; distinctiveness-of-image; hardness; abrasion or scratch resistance; weatherability such as UV resistance; impact strength; thermal stability, namely, resistance to extreme high and low temperatures; gasoline and acid resistance; cleanability; adhesion to the underlying car body panel; resistance to water and humidity exposure; and hiding ability or opacity of the paint coat. Accordingly, there has been significant interest on the part of manufacturers to produce a protective and decorative coating on these panels and parts that will meet or exceed consumers demands and expectations.  
       [0003] The traditional painting technique for thermoplastic exterior automotive body panels and trim parts involved spray painting which produced potentially dangerous levels of airborne pollutants, wasted significant amounts of paint, and resulted in unacceptable variations in quality control. Because of these disadvantages, there has been a growing trend toward eliminating the need for the spray painting operation, in favor of more efficient and economical alternatives.  
       [0004] One approach has involved the use of a preformed thermoplastic sheet material that can be bonded, attached, or otherwise fastened to the panel or part to provide the requisite protective and decorative coating that will equal or exceed the quality of a conventionally spray-painted surface. However, exterior automotive panels and trim parts present a particular problem in view of the difficulty of smoothly adhering a flexible sheet material to a curved substrate and the difficulty of doing so while maintaining a uniform color intensity over the entire surface. This is even more problematic when metallic colors are desired in finishes.  
       [0005] Discussions of various laminated products, the materials employed, and the methods of making the same may be found in U.S. Pat. Nos. 4,810,540 to Ellison et al.; 4,832,991 to Hayward et al.; 4,900,611 to Carroll, Jr.; 4,921,556 to Hakiel et al.; 4,913,760 to Benson et al.; 4,913,970 to Hayward et al.; 4,918,800 to Reafler; 4,921,755 to Carroll, Jr. et al.; 4,931,324 to Ellison et al.; 4,933,237 to Krenceski et al.; 4,943,680 to Ellison et al.; 5,026,448 to Reafler et al.; 5,034,077 to Pata; 5,034,269 to Wheeler; 5,034,275 to Pearson et al.; 5,035,940 to Winton et al.; 5,100,728 to Plamthottam et al.; 5,114,514 to Landis; 5,114,789 to Reafler; 5,118,372 to Spahn; 5,125,994 to Harasta et al.; 5,132,148 to Reafler; 5,165,976 to Newing et al.; 5,192,609 to Carroll, Jr.; 5,215,811 to Reafler et al.; 5,215,826 to Shimanski et al.; 5,268,215 to Krenceski et al., 5,286,528 to Reafler; 5,318,815 to Newing et al.; 5,342,666 to Ellison et al.; 5,514,427 to Ellison et al.; 5,518,786 to Johnson et al.; 5,536,539 to Ellison et al.; 5,539,057 to Giroux; 5,574,094 to Malucelli; 5,585,434 to DeNicola et al.; 5,585,448 to Resconi et al.; 5,593,759 to Vargas et al.; 5,653,927 to Flynn et al.; 5,698,487 to Sacchetti et al.; 5,707,697 to Spain et al.; 5,725,712 to Spain et al.; 5,750,234 to Johnson et al., 5,759,940 to Sacchetti et al.; 5,817,707 to DeNicola et al.; 5,849,653 to Dall&#39;Occo et al.; and 5,859,104 to Becker, the entire specifications of which are expressly incorporated herein by reference.  
       [0006] Some manufacturers have attempted to produce a flexible and stretchable sheet material having these capabilities through the application of one or more paint layers to the surface of a thermoformable thermoplastic support. However, it is believed that these efforts have resulted in products having numerous coating defects and in which the paint layer does not have the high degree of uniformity which permits the sheet material to undergo the stresses of thermoforming and yet meet the exacting standards of an exterior automotive finish. Thus, the amount and depth of draw is limited, thus representing a limitation on the types and configurations of exterior automotive panels and trim parts that may be produced with these sheet materials.  
       [0007] Several polyolefin resin manufacturers have developed “mold in” color resins for exterior automotive parts that can be injection molded. The problem that occurs with these “mold in” color resins is that the outermost surfaces are relatively soft due to the nature of the resin, and thus are easily scratched, or otherwise blemished. Another problem that occurs with these “mold in” color resins is gloss level retention during the injection molding process.  
       [0008] In order to overcome these disadvantages, manufacturers have recently employed a film comprised of a scratch resistant layer having one or more layers of paint, ink, or other colorants applied to one surface thereof. This colored, scratch resistant laminated product is then bonded, attached, or otherwise fastened to the underlying thermoplastic substrate to form the finished exterior automotive panel or trim part. However, the process of applying paint, ink, or other colorants to the scratch resistant layers may potentially produce defects and unnecessarily adds to manufacturing costs, especially with respect to solvent-based paints, inks, and other colorants. Additionally, the paint, ink, or other colorant will have a tendency to wash or fade because of the stress from stretching of the film during thermoforming.  
       [0009] Therefore, there exists a need for a flexible, thermoformable laminated sheet material and method of making the same, that can be attached to various substrates, including exterior automotive body panels and trim parts, as a protective and decorative covering, wherein the sheet material can be formed into various shapes and configurations while retaining uniform color intensity and scratch resistance.  
       SUMMARY OF THE INVENTION  
       [0010] In accordance with one embodiment of the present invention, the present invention provides a protective and decorative sheet material for application to substrates comprised of: (1) a base coat layer comprising a colorant-containing thermoplastic resin system, the colorant being substantially uniformly distributed throughout the colorant-containing thermoplastic resin system; (2) a top coat layer; and (3) an adhesion promoting layer disposed between the base coat layer and the top coat layer.  
       [0011] In accordance with another embodiment of the present invention, the present invention provides a laminate product comprised of: (1) a substrate; (2) a base coat layer adjacent to the substrate, the base coat layer comprising a colorant-containing thermoplastic resin system, the colorant being substantially uniformly distributed throughout the colorant-containing thermoplastic resin system; (3) a top coat layer; and (4) an adhesion promoting layer disposed between the base coat layer and the top coat layer.  
       [0012] In accordance with another embodiment of the present invention, the present invention provides a protective and decorative sheet material for application to substrates comprised of: (1) a base coat layer comprising a colorant-containing thermoplastic resin system, the colorant being substantially uniformly distributed throughout the colorant-containing thermoplastic resin system, and a chlorinated compound applied to at least a portion of at least one surface of the base coat layer; and (2) a top coat layer disposed on the at least one surface of the base coat layer having the chlorinated compound applied thereto.  
       [0013] In accordance with another embodiment of the present invention, the present invention provides a protective and decorative sheet material for application to substrates comprised of: (1) a base coat layer comprising a colorant-containing thermoplastic resin system, the colorant being substantially uniformly distributed throughout the colorant-containing thermoplastic resin system, and a chlorinated compound mixed throughout the colorant-containing thermoplastic resin system; and (2) a top coat layer disposed on the base coat layer.  
       [0014] In accordance with another embodiment of the present invention, the present invention provides a laminate product comprised of: (1) a substrate; (2) a base coat layer adjacent to the substrate, the base coat layer comprising a colorant-containing thermoplastic resin system, the colorant being substantially uniformly distributed throughout the colorant-containing thermoplastic resin system; a chlorinated compound applied to at least a portion of at least one surface of the base coat layer; and (3) a top coat layer disposed on the at least one surface of the base coat layer having the chlorinated compound applied thereto.  
       [0015] In accordance with another embodiment of the present invention, the present invention provides a laminate product comprised of: (1) a substrate; (2) a base coat layer adjacent to the substrate, the base coat layer comprising: a colorant-containing thermoplastic resin system, the colorant being substantially uniformly distributed throughout the colorant-containing thermoplastic resin system, and a chlorinated compound mixed throughout the colorant-containing thermoplastic resin system; and (3) a top coat layer disposed on the base coat layer.  
       [0016] In accordance with another embodiment of the present invention, the present invention provides a method of making a protective and decorative sheet material for application to a substrate comprising the steps of: (1) providing a base coat layer comprising a colorant-containing thermoplastic resin system, the colorant being substantially uniformly distributed throughout the colorant-containing thermoplastic resin system; (2) providing an adhesion promoting layer; (3) laminating the adhesion promoting layer onto the base coat layer; (4) providing a top coat layer; and (5) laminating the top coat layer onto the adhesion promoting layer.  
       [0017] In accordance with another embodiment of the present invention, the present invention provides a method of making a laminate product comprising the steps of: (1) providing a base coat layer comprising a colorant-containing thermoplastic resin system, the colorant being substantially uniformly distributed throughout the colorant-containing thermoplastic resin system; (2) providing an adhesion promoting layer; (3) laminating the adhesion promoting layer onto the base coat layer; (4) providing a top coat layer; (5) laminating the top coat layer onto the adhesion promoting layer to form a laminate product; (6) providing a substrate; and (7) joining the laminate product to the substrate.  
       [0018] In accordance with another embodiment of the present invention, the present invention provides a method of making a protective and decorative sheet material for application to a substrate, comprising the steps of: (1) providing a base coat layer comprising a colorant-containing thermoplastic resin system, the colorant being substantially uniformly distributed throughout the colorant-containing thermoplastic resin system, and a chlorinated compound applied to at least a portion of at least one surface of the base coat layer; (2) providing a top coat layer; and (3) laminating the top coat layer onto the at least one surface of the base coat layer having the chlorinated compound applied thereto.  
       [0019] In accordance with another embodiment of the present invention, the present invention provides a method of making a protective and decorative sheet material for application to a substrate, comprising the steps of: (1) providing a base coat layer comprising a colorant-containing thermoplastic resin system, the colorant being substantially uniformly distributed throughout the colorant-containing thermoplastic resin system, and a chlorinated compound mixed throughout the colorant-containing thermoplastic resin system; (2) providing a top coat layer; and (3) laminating the top coat layer onto the base coat layer.  
       [0020] In accordance with another embodiment of the present invention, the present invention provides a method of making a laminate product, comprising the steps of: (1) providing a base coat layer comprising a colorant-containing thermoplastic resin system, the colorant being substantially uniformly distributed throughout the colorant-containing thermoplastic resin system, and a chlorinated compound applied to at least a portion of at least one surface of the base coat layer; (2) providing a top coat layer; (3) laminating the top coat layer onto the at least one surface of the base coat layer having the chlorinated compound applied thereto to form a laminate product; (4) providing a substrate; and (5) joining the laminate product to the substrate.  
       [0021] In accordance with another embodiment of the present invention, the present invention provides a method of making a laminate product, comprising the steps of: (1) providing a base coat layer comprising a colorant-containing thermoplastic resin system, the colorant being substantially uniformly distributed throughout the colorant-containing thermoplastic resin system, and a chlorinated compound mixed throughout the colorant-containing thermoplastic resin system; (2) providing a top coat layer; (3) laminating the top coat layer onto the base coat layer to form a laminate product; (4) providing a substrate; and (5) joining the laminate product to the substrate. 
     
    
    
     [0022] A more complete appreciation of the various embodiments. and aspects of the present invention and the scope thereof can be obtained from a study of the accompanying drawings, which are briefly summarized below, the following detailed description of the invention, and the appended claims.  
     BRIEF DESCRIPTION OF THE DRAWING  
     [0023]FIG. 1 is an enlarged partial cross-sectional view of a sheet material of the present invention.  
     [0024]FIG. 2 is a partial perspective view illustrating a method of making the sheet material of FIG. 1.  
     [0025] The same reference numerals refer to the same parts throughout the various Figures. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
     [0026] The invention will be described with reference to providing protective and decorative finishes on exterior automotive panels and trim parts, such as but not limited to, bumpers, fascias, doors, hoods, trunks, mirror housings and body side moldings. However, it should be understood that there are many other substrates to which the sheet material of the invention can be applied.  
     [0027] Referring to FIG. 1, the laminate product or sheet material  10  of the present invention is comprised primarily of a base coat layer  12 , an adhesion promoting layer  14 , and a top coat  16 . The sheet material  10  is preferably flexible and thermoformable.  
     [0028] The base coat layer  12  is preferably comprised of a colorant-containing thermoplastic resin system, with the colorant  18  being substantially uniformly distributed throughout the colorant-containing thermoplastic resin system. By distributing a sufficient quantity of colorant throughout the thermoplastic resin system, the base coat layer  12  is rendered substantially opaque, even after significant stretching of the sheet material  10  has occurred, for example, during thermoforming.  
     [0029] By the term “color-containing thermoplastic resin system” as used herein is meant a system that comprises at least two elements: (1) at least one pigment or dye; and (2) at least one thermoplastic material. Other compounds, materials or agents may be employed in this system as well, especially those conventionally used in coloring thermoplastic resins or in formulating color concentrates. By way of example (but without any suggestion of limitation) the color-containing thermoplastic resin systems useful in the present invention may additionally employ a plurality of organic or inorganic pigments, dyes, or mixtures thereof. These may be incorporated into the thermoplastic resin as conventional dry or liquid color concentrates, super-concentrates, or pre-colored resin systems. Additionally, other optional materials may be added to the color-containing thermoplastic resin system including, but not limited to, additives such as antioxidants, antiozonants, and ultraviolet absorbers; coupling agents; curing agents; flame retardants; heat stabilizers; impact modifiers; lubricants; plasticizers; preservatives; processing aids; reinforcements; and fillers.  
     [0030] Preferably, the thermoplastic material of the base coat layer  12  is comprised of one or more types of polyolefins. Polyolefins are generally defined as resinous materials made by the polymerization of olefins, such as polyethylene from ethylene, polypropylene from propylene, polybutene from butylene, and so on. Polyolefins are generally characterized as having good chemical resistance, stress cracking resistance, weatherability, reduced density, improved processability, and enhanced ductility. Although polyolefins are preferred, other materials such as nanocomposites based on clay materials (e.g., smectite clay) are also useful in the practice of the present invention.  
     [0031] In accordance with a preferred embodiment of the present invention, the thermoplastic material of the base coat layer  12  is comprised of polypropylene, or alternatively one or more types of olefenic alloys, such as, but not limited to, acrylic-based or styrenic-based olefinic resin alloys. Additionally, other materials such as, but not limited to, acrylics, polycarbonates, acrylonitrile-butadiene-styrene (ABS), and nylon may be used as the thermoplastic material of the base coat layer  12 .  
     [0032] In accordance with a highly preferred embodiment of the present invention, the base coat layer  12  is comprised of either HIVALLOY W™ or HIVALLOY G™ (readily commercially available from Montell Technology Company BV, Hoofddorp, Netherlands), BEXLOY™ W (readily commercially available from E. I. du Pont de Nemours and Company, Wilmington, Del.), or DEXFLEX™ E-1501 TF (readily commercially available from Solvay Engineered Polymers, Auburn Hills, Mich.).  
     [0033] The general properties of the HIVALLOY W™ and HIVALLOY G™ brand materials are presented in Table I, below:  
                                   TABLE I                                   General                       Properties   ASTM   Units   Value                          Specific Gravity   D792   g/cc   0.91 to 0.98           Tensile Strength   D638   psi   3000 to 5200           Elongation @   D638   %      20 to &gt;400           Break           Elongation @   D638   %    6 to 25           Yield           Flexural Modulus   D790A   kpsi   110 to 280           Flexural Strength   D790A   psi   3000 to 7900           HDT @ 66 psi   D648   ° F.   170 to 205           HDT @ 264 psi   D648   ° F.   118 to 140           Notched Izod @   D256   ft-lb/in   1.0 to 8.0           73° F.           MFR (230/3.8)   D1238   dg/min    2 to 25           CLTE   D696       4.1 to 9.5           Water Absorption       %   &lt;0.2 to &lt;0.5           Mold Shrinkage   D955   in/in   .008 to .016                      
 
     [0034] The general properties of the BEXLOY™ W brand material are presented in Table II, below:  
                               TABLE II                       General                       Properties   ASTM   Units   Temperature   Value                                                        Flexural   D790   MPa   23°   C.   682       Modulus       kpsi   73°   F.   100       Specific   D792       23°   C./73° F.   0.97       Gravity       Tensile   D638   MPa   23°   C.   20       Strength       psi   73°   F.   2900       Elongation @   D638   %   23°   C./73° F.   &gt;400       Break       Heat Sag   D3769   mm   82°   C.   13               inches   180°   F.   0.5       Tear   D624   kN/m   23°   C.   164       Resistance       lb/in   73°   F.   935       Notched Izod   D256   J/m   −30°   C.   854       Impact       ft · lb/in   −22°   F.   16       Gardner   D3029   J   −30°   C.   &gt;36       Impact       in · lb   −22°   F.   &gt;320       Rheometric       J   23°   C.   22       Impact       in · lb   73°   F.   194               J   −30°   C.   18               in · lb   −22°   F.   159       Shrinkage   D955   %           1.2       Coefficient   D831   μm/m, ° C.   −30° to   80° C.   84       of Linear       in/in, ° F.   −22° to   176° F.   4.6 × 10 −5         Thermal       Expansion                  
 
     [0035] The general properties of the DEXFLEX™ E-1501 TF brand material are presented in Table III, below:  
                                   TABLE III                                   General                       Properties   ASTM   Units   Value                                                            Hardness   D2240   Shore D   65           Specific Gravity   D792       0.95           Melt Flow Rate   D1238   g/10 min   0.92           Flexural Modulus   D790   kpsi   150           Tensile Strength   D638   psi   3800           Elongation @   D638   %   500           Break           Tear Strength   D1004   lb/in   700           Gardner Impact   D3028   in · lb   &gt;300           @ −30° C.                      
 
     [0036] The base coat layer  12  is preferably formed into thin flexible sheets or rolls in preparation for the lamination process which will be described in detail herein. The thickness of the base coat layer  12  is preferably in the range of about 0.010 inches to about 0.250 inches. In accordance with a preferred embodiment of the present invention, the thickness of the base coat layer  12  is preferably in the range of about 0.020 inches to about 0.060 inches. It should be noted that the base coat layer  12  may be configured to any desired  
     [0037] The general properties of the DEXFLEX™ E-1501 TF brand material are presented in Table III, below:  
                                   TABLE III                                   General                       Properties   ASTM   Units   Value                                                            Hardness   D2240   Shore D   65           Specific Gravity   D792       0.95           Melt Flow Rate   D1238   g/10 min   0.92           Flexural Modulus   D790   kpsi   150           Tensile Strength   D638   psi   3800           Elongation @   D638   %   500           Break           Tear Strength   D1004   lb/in   700           Gardner Impact   D3028   in · lb   &gt;300           @ −30° C.                      
 
     [0038] The base coat layer  12  is preferably formed into thin flexible sheets or rolls in preparation for the lamination process which will be described in detail herein. The thickness of the base coat layer  12  is preferably in the range of about 0.010 inches to about 0.250 inches. In accordance with a preferred embodiment of the present invention, the thickness of the base coat layer  12  is preferably in the range of about 0.020 inches to about 0.060 inches. It should be noted that the base coat layer  12  may be configured to any desired thickness depending on the particular application.  
     [0039] In order to secure the top coat layer  16  to the base coat layer  12 , it is generally necessary to employ an adhesion promoting layer  14  that is disposed therebetween. In this manner, the top coat layer  16  and the base coat layer  12  do not come into contact with one another. Rather, it is the adhesion promoting layer  14  that actually allows for the formation of the laminate product  10  of the present invention. The adhesion promoting layer  14  (also referred to as a tie layer, adhesive primer layer, etc.) is generally comprised of an adhesive material that is capable of adhering to both the top coat layer  16  and the base coat layer  12 . Therefore, the adhesion promoting layer  14  must be comprised of material or materials that are compatible with the top coat layer  16  and the base coat layer  12  in order to achieve the desired degree of adhesion between the particular layers. Preferably the adhesive material is completely, or at least substantially, transparent so as not to obscure the colorant contained in the base coat layer  12 .  
     [0040] In accordance with a preferred embodiment of the present invention, the adhesion promoting layer  14  is comprised of a chlorinated polyolefin/acrylic material. In accordance with a highly preferred embodiment of the present invention, the adhesion promoting layer  14  is actually comprised of two discrete layers wherein the first layer is comprised of chlorinated polyolefin and the second layer is comprised of acrylic material. An example of a suitable two layer system of this type is readily commercially available from Maple Roll Leaf (Windsor, Ontario, Canada) under the product designation X-275. The X-275 material, which is proprietary in nature, is comprised of a layer of modified chlorinated polyolefin and an adjacent layer of a high molecular weight acrylic copolymer. It should be noted that standard adhesives additives, such as magnesium silicate, may be added to the adhesion promoting layer  14  to enhance its performance and appearance. During the lamination process, it is intended that the chlorinated polyolefin layer is placed against the base coat layer  12 , and the acrylic layer is placed against the top coat layer  16 .  
     [0041] The adhesion promoting layer  14  is preferably formed into thin flexible sheets or rolls in preparation for the lamination process which will be described in detail herein. The thickness of the adhesion promoting layer  14  is preferably in the range of about 0.03 grams/m 2  to about 1.5 grams/m 2 , still more preferably in the range of about 0.1 grams/m 2  to about 1.0 gram/m 2 , and most prefereably in the range of about 0.3 grams/m 2  to about 0.5 grams/m 2 . It should be noted that other thicknesses are envisioned depending on the particular application.  
     [0042] The top coat layer  16  is preferably completely, or at least substantially, transparent so as not to obscure the colorant contained in the base coat layer  12 . Additionally, the top coat layer  16  is preferably highly scratch resistant so as to avoid nicks, scrapes, an other blemishes from forming on the surface of the laminate product  10  of the present invention. In accordance with a preferred embodiment of the present invention, the top coat layer  16  is comprised of a thermoplastic material, such as, but not limited to, polyvinylidene fluoride (PVDF), readily commercially available under the tradename KYNAR™ from San Diego Plastics, Inc. (San Diego, Calif.), polyvinyl fluoride (PVF), readily commercially available under the tradename TEDLAR™ from E. I. du Pont de Nemours and Company (Wilmington, Del.), or acrylic, readily commercially available under the tradename KORAD™ from Polymer Extruded Products (Newark, N.J.). Alternatively, polyurethane, especially cross-linked polyurethane, may be used as the top coat layer  16 .  
     [0043] The top coat layer  16  is preferably formed into thin flexible sheets or rolls in preparation for the lamination process which will be described in detail herein. The thickness of the top coat layer  16  is preferably in the range of about 0.0005 inches to about 0.010 inches. In accordance with a preferred embodiment of the present invention, the thickness of the top coat layer  16  is in the range of about 0.001 inches to about 0.005 inches. It should be noted that other thicknesses may be employed, depending on the particular application.  
     [0044] In accordance with another embodiment of the present invention, a coating of chlorinated compound (e.g., chlorinated polyolefin) is applied (e.g., rolling, spraying, etc.) onto the top surface of the base coat layer  12 , instead of applying the previously described adhesion promoting layer  14 . The top coat layer  16  is then directly applied onto the coated top surface of the base coat layer  12 . The chlorinated compound must be compatible with both the base coat layer  12  and the top coat layer  16  in order to achieve the desired degree of adhesion between the two layers.  
     [0045] In accordance with yet another embodiment of the present invention, the chlorinated compound (e.g., chlorinated polyolefin) is mixed throughout the base coat layer  12 , instead of only being applied to the top surface thereof. The top coat layer  16  is then applied onto the top surface of the base coat layer  12 . As previously mentioned, the chlorinated compound must be compatible with both the base coat layer  12  and the top coat layer  16  in order to achieve the desired degree of adhesion between the two layers.  
     [0046] To illustrate the enhanced scratch resistance of the top coat layer  16  of the present invention, a specimen of the laminate product  10  of the present invention was submitted to an independent laboratory for analysis. A crock mar resistance test was performed in accordance with Chrysler laboratory procedure LP-463PB-54-01. Dry BON-AMI™ cleanser was applied to approximately one half of the specimen which was then rubbed with a 5×5 centimeter wool felt cloth for ten times using an Atlas AATCC mar tester. The specimen&#39;s original 20° gloss was 62.3, whereas the marred 20° gloss was 40.2. Therefore, the mar resistance (marred/original gloss×100) was 64.5.  
     [0047] Referring to FIG. 2, the manufacture of the laminate product  10  of the present invention will now be described in detail. Preferably, the base coat layer  12 , adhesion promoting layer  14 , and top coat  16  are in roll form and are mounted on the axles of a conventional laminating apparatus  20 , preferably employing quartz heated silicone rolls.  
     [0048] In this view, the base coat layer  12  is being fed through one end of the laminating apparatus  20  by the action of one or more roller assemblies  22 . The head pressure is preferably in the range of about 60 to about 120 pounds per square inch. The feed speed may vary; however, about 10 to about 15 feet per minute is preferable. As the base coat layer  12  advances, the roll containing the adhesion promoting layer  14  is actuated so as to apply the adhesion promoting layer  14  onto the top surface of the base coat layer  12 .  
     [0049] The base coat layer  12 /adhesion promoting layer  14  laminate is then fed through a heated (e.g., 390-500° F.) calendering roller assembly  24  to ensure that a strong bond (chemical and/or physical) is established between the base coat layer  12  and the adhesion promoting layer  14 . The top surface of the adhesion promoting layer  14  is preferably provided with a releasable liner  13  so as to prevent the top surface of the adhesion promoting layer  14  from sticking to the roller assembly  24 . Once the base coat layer  12 /adhesion promoting layer  14  laminate is fed through the roller assembly  24 , a rewind mechanism  25  removes the liner  13  from the top surface of the adhesion promoting layer  14  in preparation for the application of the top coat layer  16 .  
     [0050] As the base coat layer  12 /adhesion promoting layer  14  laminate advances, the roll containing the top coat layer  16  is actuated so as to apply the top coat layer  16  onto the top surface of the adhesion promoting layer  14 . The base coat layer  12 /adhesion promoting layer  14 /top coat layer  16  laminate is then fed through a heated (e.g., 390-500° F.) calendering roller assembly  26  to ensure that a strong bond (chemical and/or physical) is established between the top coat layer  16  and the adhesion promoting layer  14 . In this manner the laminate product  10  of the present invention is formed and fed further down the line by an additional roller  28 .  
     [0051] The laminate product  10  of the present invention can be processed in any number of ways, including, but not limited to thermoforming, vacuum forming, and insert molding. As the laminate product  10  is in the form of a relatively thin and flexible sheet, it can easily be adapted to the contours of various thermoplastic or metallic substrates, such as, but not limited to automotive body panels and trim parts. Additionally, because the laminate product  10  is thermoformable, it may be shaped into a number of complex configurations and then placed into an injection molding apparatus whereupon a substrate (e.g., thermoplastic resin) may be laminated or otherwise bonded to the laminate product  10  of the present invention. In this manner, complex, yet sturdy components may be quickly and inexpensively made without compromising quality or safety. For example, the laminate product  10  of the present invention will allow thicker laminates to be formed in deep draw areas like bumpers and fascias, and would be thick enough to be structurally stable without insert molding. It will be appreciated that the depth of draw is dependent on several factors, including, but not limited to, the thickness of the base coat layer of the laminate product as well as the thickness of any substrate to which the laminate product is joined to. For instance, if there is “read-through” or discontinuity in opacity in the laminate product, the thickness of the base coat layer can be increased, or alternatively, a similarly colored thermoplastic resin can be injection molded behind the laminate product.  
     [0052] The foregoing detailed description shows that the preferred embodiments of the present invention are well suited to fulfill the objects above-stated. It is recognized that those skilled in the art may make various modifications or additions to the preferred embodiments chosen to illustrate the present invention without departing from the spirit and proper scope of the invention. Accordingly, it is to be understood that the protection sought and to be afforded hereby should be deemed to extend to the subject matter defined by the appended claims, including all fair equivalents thereof.