Thermoplastic polyolefin composite structure
First Claim
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1. A three dimensional thermoplastic polyolefin composite useful as an exterior auto or truck body part consisting essentially of the following components:
- 1. a multilayer coating consisting essentially ofa. a 10-125 micron thick layer of a glossy clear thermoplastic finish formed from a clear coating composition bonded firmly tob. a 5-75 micron thick layer of a thermoplastic pigment containing paint firmly bonded toc. a 1-25 micron thick size layer of a thermoplastic chlorinated polyolefin containing 15-50% by weight chlorine;
said multilayer coating formed by applying a layer of a clear coating composition to a polymeric film, applying a paint layer to the layer of clear coating composition and then applying a layer of the thermoplastic chlorinated polyolefin to the paint layer and curing the multilayer coating;
said multilayer being firmly bonded by lamination to2. a 250-1250 micron thick layer of a flexible extruded sheet of a thermoplastic polyolefin having a flexural modulus of about 175-2100 MPa and a melt flow rate of about 0.5-2.0 g/10 min.;
wherein the chlorinated polyolefin layer of the multilayer coating is in contact with the sheet of thermoplastic polyolefin and the polymeric sheet is removed after lamination to leave a smooth glossy surface on the clear layer and the resulting flexible sheet having the multilayer coating is thermoformed into a three dimensional structure that is bonded to3. a 500-25,000 micron thick rigid layer of a thermoplastic polyolefin resin having a modulus of about 175-2100 MPa and a melt flow rate of about 4.0-8.0 g/10 min. formed by injection molding said resin to the flexible sheet having a three dimensional structure;
wherein layers a. and b. of the multilayer form the exterior surface of the composite and have a gloss of at least 60 measured at 20° and
a distinctness of image of at least 60.
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Abstract
A thermoplastic polyolefin composite that is useful as an exterior auto or truck body part has the following layers of components:
a. a layer of a glossy clear thermoplastic finish bonded firmly to
b. a layer of a thermoplastic pigment containing paint firmly bonded to
c. a thin size layer of a thermoplastic chlorinated polyolefin that is firmly bonded to
d. a flexible sheet of a thermoplastic polyolefin resin.
A thermoformable composite sheet structure that can be made into the above laminate having the layers a.-d. of the above structure also is part of this invention.
156 Citations
25 Claims
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1. A three dimensional thermoplastic polyolefin composite useful as an exterior auto or truck body part consisting essentially of the following components:
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1. a multilayer coating consisting essentially of a. a 10-125 micron thick layer of a glossy clear thermoplastic finish formed from a clear coating composition bonded firmly to b. a 5-75 micron thick layer of a thermoplastic pigment containing paint firmly bonded to c. a 1-25 micron thick size layer of a thermoplastic chlorinated polyolefin containing 15-50% by weight chlorine; said multilayer coating formed by applying a layer of a clear coating composition to a polymeric film, applying a paint layer to the layer of clear coating composition and then applying a layer of the thermoplastic chlorinated polyolefin to the paint layer and curing the multilayer coating;
said multilayer being firmly bonded by lamination to2. a 250-1250 micron thick layer of a flexible extruded sheet of a thermoplastic polyolefin having a flexural modulus of about 175-2100 MPa and a melt flow rate of about 0.5-2.0 g/10 min.;
wherein the chlorinated polyolefin layer of the multilayer coating is in contact with the sheet of thermoplastic polyolefin and the polymeric sheet is removed after lamination to leave a smooth glossy surface on the clear layer and the resulting flexible sheet having the multilayer coating is thermoformed into a three dimensional structure that is bonded to3. a 500-25,000 micron thick rigid layer of a thermoplastic polyolefin resin having a modulus of about 175-2100 MPa and a melt flow rate of about 4.0-8.0 g/10 min. formed by injection molding said resin to the flexible sheet having a three dimensional structure; wherein layers a. and b. of the multilayer form the exterior surface of the composite and have a gloss of at least 60 measured at 20° and
a distinctness of image of at least 60. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
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Specification