Method for making formable laminated decorative sheets

Abstract

A method of making thermoplastic formable sheets laminated with a decorative film, such as one or more layers of glossy clear coat bonded to a layer of pigment containing paint. The method involves providing a thermoplastic formable plastic sheet; applying, on a surface of the plastic sheet, a layer of unsolidified decorative colorant material which forms a decorative first film; curing (if necessary) the decorative material layer to form the adherent first film bonded to the sheet; and applying, on the first film, a unsolidified second film for forming a high quality outer surface covering the decorative first film. Optionally, the decorative sheet may have a first protective layer of thermoformable plastic film removably fixed to the decorative material to protect it from damage during forming of the sheet into a formed part or panel. For automotive body trim parts or body panels, the formable laminated sheet preferably has a thickness of from generally 0.065 to generally 0.3 inches and is preferably compression formed with optional thermoforming steps included with, or in place of, compression forming. A second removable protective layer of film may be applied over the first layer to protect against damage prior to compression forming of the sheet.

Dependencies are inferred from the claim text.