Extrusion coating process for making protective and decorative films
AssigneeAvery Dennison Corporation
InventorsHoward H. Enlow, Russell J. McCready, John E. Roys, Keith L. Truog, Frederick Young
Life of this patent
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Abstract
A process for making a protective and decorative surfacing film comprises extrusion coating a solid polymeric material to form an optically clear first layer (10) on a smooth surface of a carrier sheet (12). The extrusion coated first layer is immediately cooled, followed by applying a pigmented second material (22) in thin film form. The composite paint coat is then transferred to a supportive backing, after which the carrier sheet is removed to expose the high gloss outer surface of the first layer. The second layer may be solvent cast, extrusion coated, or coextruded with the first layer.
Claims53
A process for making a protective and decorative sheet material, comprising extrusion coating a solid polymeric material from an extrusion die onto a smooth surface of a carrier sheet traveling continuously past the extruder die opening to form a first layer comprising a weatherable thermoplastic and thermoformable optically clear coat of uniform thickness on the carrier sheet;
- immediately cooling the clear coat on the traveling carrier to harden the clear coat;
- applying a pigmented second layer of a thermoplastic and thermoformable polymeric material in thin film form to the first layer and hardening the second layer to form a composite paint coat in which the first and second layers are bonded to each other while supported by the carrier sheet;
- and separating the carrier sheet from the composite paint coat to expose an outer surface of the protective first layer as a transparent protective outer coat for the pigmented second layer, the outer surface of the protective first layer having a high gloss and a high distinctness-of-image of exterior automotive quality transferred to it from its previous contact with the carrier sheet.
A process for making a protective and decorative sheet material, comprising extrusion coating a solid polymeric material from an extrusion die onto a smooth surface of a carrier sheet traveling continuously past the extruder die opening to form a first layer comprising a weatherable thermoplastic and thermoformable optically clear coat of uniform thickness on the carrier sheet;
- cooling the extrusion coated first layer to harden the first layer on the carrier sheet;
- applying a pigmented second layer of a thermoplastic and thermoformable polymeric material in thin film form to the hardened first layer to form a composite paint coat in which the first and second layers are bonded to each other while supported by the release-coated carrier sheet;
- laminating a thermoformable polymeric supportive sheet to the second layer side of the composite paint coat;
- and separating the carrier sheet from the composite paint coat to expose an outer surface of the first layer as a transparent protective outer coat for the pigmented second layer, the outer surface of the protective first layer having a high gloss and high distinctness-of-image of exterior automotive quality transferred to it from its previous contact with the carrier sheet.
A process for making an extruded clear coat film having an optical clarity sufficient for use as a weatherable exterior automotive paint film, the process comprising preparing a starting material comprising an extrudable weatherable polymeric material prepared from a blend of weatherable polymers, and extruding the starting material in an extruder to form at the extruder die exit opening an extruded clear coat film, the extruded starting material being maintained at a temperature below the gel formation temperature of the weatherable polymers contained in the blended starting material, said temperature being maintained during preparation of the starting material and during extrusion into the clear coat film, thereby minimizing optical defects in the extruded film sufficient for exterior automotive paint film requirements.
A process for making an extruded film of high optical clarity comprising preparing an extrudable polymeric material from a blend of weatherable polymers to form a starting material, and extruding the starting material to form a the extruder die exit opening and optically clear thermoformable weatherable film with a defect level of less than about five defects based on the C-charting standard of measurement, said starting material being extruded at an operating temperature below the gel formation temperature of the polymeric materials contained in the starting material.
Dependencies are inferred from the claim text.