Trim component including a metalized polyester film and substrate having curled edges

A method of making a trim component, the method comprising the steps of:

• providing a polyester film carrier for supporting layers of coatings, the film carrier having a top surface and a bottom surface;
• exposing at least the bottom surface of the film carrier to an inert gas to remove impurities therefrom;
• depositing a metallized coating on the bottom surface of the carrier for simulating the appearance of a metallized component;
• applying an adhesive layer on the metallized coating for securing the metallized coating and film carrier to a substrate, the substrate having first and second surfaces;
• securing the metallized coating and film carrier to the first surface of the substrate, the adhesive layer being disposed between the metallized coating and the substrate;
• configuring the substrate and attached film carrier and metallized coating into a final component shape such that the substrate has edges defining its outer periphery;
• curling the edges of the substrate (and attached film carrier and metallized coating) for providing a wear resistant and weather resistant seal between the carrier and the substrate;
• securing a support plastic to the second surface of the substrate, thereby forming the trim component, wherein the curled edges of the substrate provide a wear resistant and weather resistant seal between the carrier and the substrate in that the curled edges protect against the penetration of water or other foreign matter in between the layers of the trim component;
• and
• treating the top surface of the film carrier with a protective coating.

A trim component comprising a laminate and a support plastic,

• wherein the laminate comprises a protective layer;
• a metallized component;
• and a polyester film carrier, the carrier having a top and bottom surface, the bottom surface having been treated with an inert gas to remove impurities therefrom;
• wherein the protective layer is disposed on the top surface of the carrier, and the metallized coating is deposited on the bottom surface of the carrier for simulating the appearance of a metallized component;
• wherein the support plastic having a predetermined configuration is adhered to the metallized coating of the laminate, an adhesive layer being disposed between the metallized coating and the support plastic, the laminate and support plastic thereby defining the trim component;
• and
• wherein the edges at the outer periphery of each of the layers of the laminate are curled in the direction of the support plastic to provide a wear resistant and weather resistant trim component in that the curled edges protect against the penetration of water or other foreign matter in between the layers of the trim component.

A method of making a trim component, the method comprising the steps of:

• providing a polyester film carrier for supporting layers of coatings, the film carrier having a top surface and a bottom surface;
• exposing at least the bottom surface of the film carrier to an inert gas to remove impurities therefrom;
• depositing a metallized coating on the bottom surface of the carrier for simulating the appearance of a metallized component;
• applying an adhesive layer on the metallized coating for securing the metallized coating and film carrier to a support plastic;
• disposing the metallized film carrier in between two injection mold plates, wherein one mold plate contains a mold for receiving plastic to form a support plastic having a predetermined configuration, and wherein the film carrier is so disposed between the mold plates that the adhesive layer of the film carrier faces the mold plate containing the mold;
• closing the injection mold plates together, thereby sealing the metallized film inside the plates;
• extruding a support plastic into the mold so that the metallized film carrier is adhesively attached to the support plastic;
• and
• treating the top surface of the film carrier with a protective coating.

A trim component comprising a laminate, a substrate having first and second surfaces, and a support plastic,

• wherein the laminate comprises a protective layer;
• a metallized coating;
• and a polyester film carrier sandwiched between the protective layer and the metallized coating, the film carrier having a top and bottom surface, the bottom surface having been treated in a vacuum chamber with an inert gas to remove impurities therefrom;
• wherein the protective layer is disposed on the top surface of the carrier;
• and wherein the metallized coating is deposited on the bottom argon-treated surface of the carrier for simulating the appearance of a metallized component;
• wherein an adhesive layer is disposed on the metallized coating of the laminate, the adhesive layer comprising a tie coat and an adhesive, wherein the tie coat is first applied to the metallized coating of the laminate and the adhesive is applied over the tie coat;
• wherein the first surface of the substrate is disposed on the adhesive layer and thereby secured to the metallized coating of the laminate;
• and
• wherein the second surface of the substrate is secured to the support plastic, thereby defining the trim component.