Note: Descriptions are shown in the official language in which they were submitted.
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BACKGROUND OF THE INVENTION
Field of the Invention:
The present invention relates to reflective decorat;ve
laminates, and more particularly to such laminates as are
useful in applications requiring exposure to mechanical
stress and environmental extremes.
Description of the Prior Art:
A variety of decorativeg reflective laminates prepared with
a variety of resin materials, have been developed and in exist-
tence for some time . With the increasing concern forsafety and weight reduction, that has developed in the
automotive industry, for example, the use of such re-
flective laminates in place of reflective articles prepared
entirely from metal, has been on the increase. Thus,
structures such as bumpers, side trim, grill work and the
like, previously prepared from relatively rigid and heavier
chromium-plated metals, are being replaced by the lighter
weight resinous materials.
While wide-spread employment of resinous materials exists,
their use has been primarily in the instance where pigmented
non-reflective hardware such as bumpers, and the like, is
acceptable in the design of the vehicle~ In those instances
where reflective surfaces are desired, however, the manu-
facturers tend to continue their use of the conventional
plated metal, because they find that the reflective sur-
faces prepared from resinous laminates tend to be of in-
ferior brightness and reflectivity, and frequently exhibit
surface defects when exposed to mechanical impact, as
well as deterioration of the metallic layer after relatively
short exposure to atmospheric air and sunlight.
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A variety of laminates specifically designed for auto-
motive application have been developed, all of which have
attempted to remedy the aforementioned deficiencies, by
providing, in pertinent part, a reflective metal layer,
usually vapor deposited upon a transparent resin film,
with the resulting metal coated film bonded adhesively to
one or more further resin films, so that the metal layer
is presumably securely disposed within the resulting
laminates. Variations on this construction are illustrated
in the Following U.S. Patents: 4,275,099; ~,235,949;
4,101,698i 3,811,989, and 3,720,567. Naturally, the fore
going listing is illustrative only, as other patents, and
related publications,illustrate yet further variations in
construction and preparation of such laminates.
Of the patents listed, U~S. Paten~ 4,275,099 to Dani is
of particular interest, as it discloses in its general
discussion, a laminate construction that is presently
popular, that of the tri-laminate. Dani describes this
construction as essentially three-ply, constituted of an
~0 aluminized polyester film, adhesively bonded to outer
polyvinylfluoride film and bonded on its opposite side
to a base layer of what patentee terms a "virgin vinyl
resin". The patentee states further, that the tri-laminate
maybe either heat fused or otherwise adhesively bonded to
a three dimensional extrusion, to form products such as
automotive trim strips and the like.
The deficiencies of this state of the art construction
are also noted by Dani, in that pa~entee remarks that the
laminated products tend to delaminate in use after
relatively short exposure to outside environments.
Dani notes that delamination frequently occurs at
the adhesive interface between the metallized surface
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and the next adjacent resin film, and proposes a specific
adhesive formulation that purportedly remedies this defect.
In addition to those deficiencies noted by Dani, the pre-
sent inventors found that the commercial production of
the known tri-laminates was exceeding difficult if not
impossible, when attempts were made to adapt these tr;-
laminates to the preparation of automotive accessories
by thermo forming techniques. Thus, it was observed that
when the temperatures of the thermo forming operation fluctu-
ated outside illustrative tolerances of about 5 F, theresulting products exhibited surface crazing, the de-
velopment of a haze in the resin films that reduced bright-
ness and reflectivity, and an effect known as "rainbow",
i.e., a multi-color hue that appears due to the distortion
of the polyester film during the thermo forming process.
Further, the appearance of any of the foregoing defects
would result in the reiection by automobile manufacturers
of products having these defects.
A further problem, noted by Dani, and others in the art,
comprises the susceptibility of the resin laminate to
attack and rapid deterioration upon exposure to ultra~
violet light. Dani proposes to include an ultra-violet
inhibitor in the polyester film to remedy this defect.
The present inventors have fQund, however, that the ad-
hesive utilized in the laminates presently known, havegenerally low resistance to deterioration from exposure
to ultra-violet light, and therefore fail within an
unacceptably short period of time after their installation.
Further, the prior art adhesives appear to attack the
adjacent metal layer and to cause it to corrode, with the
result that desired appearance and laminate integrity
rapidly deteriorate
.
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A need therefore exists for the development of an im-
proved laminate and associated method of preparation
that can efficiently and economically cure the noted
product deficiencies.
SUMMARY OF THE INVENTIO~I
In accordance wlth the present invention, a decorative
metallized laminate exhibiting improved brilliance,
reflectance and weatherability is disclosed which com-
prises a base layer prepared from a thermo formable
resin film having both surfaces thereof coated with a
thin,adherent layer of metal, and an ou~e.r, protective
capping layer prepared from a film having at least one
surface treated for receptivity to adhesive bonding
and resistance to attack by ultra violet radiation,
the capping layer adhesively bonded to one of the metallized
surfaces of the base layer. A pressure and heat sensi-
tive elastomeric adhesive coating, also resistent to
attack by ultra violet radiation and harmless to the
metal layers, is disposed between the capping layer
and the metallized surface of the base layer, and forms
the bond therebetween. The present laminate maybe
bonded to a compatable thermo-formable resin backing layer
that may be laminated to the free metallized surface of
the base layer.
The base layer is a non-oriented resin film prepared
from material selec~ed from the group consisting of amorphous
polyester resins, polycarbonate resins, substituted
and unsubstituted vinyl polymers, and their co-polymers.
Preferably, the non oriented resin comprises an amorphous
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polyester, such as polyethylene terephthalate and ranges
in th;ckness from about 3 to about 8 mils. The metal
layers may be applied by conventional techniques, such as
vapor deposit;on, and may include chromium, nickel, iron,
aluminum, and others, with aluminum preferred.
The capping layer may be a material selected from the
group consisting of fl uorinated vinyl polymers, fluorinated
polyolefins, and polyesters treated for resistance to
ultra-violet radiation. Preferably, the capping layer
comprises a polyvinylfluoride.
The adhesive coating maybe a silicone resin or an acrylic
resin, and preferrably includes a catalyst in amount
ranging from about 2% to about ~% by weight of the resin
solids of the adhesive. Preferrably, the adhesive is a
silicone resin such as a substituted polysiloxane, and
the catalyst is a silicone compound as wellO
The present invention includes a method for preparing the
decorative metallic laminate, comprising the steps of
applying the metal layer to one surface of the base layer,
adhesively bonding the capping layer to the metallized
surface of the base layer and thereafter metallizing the
free surface of the base layer. The resulting laminate
may then be bonded by standard laminating techniques,
such as extrusion lamination, to a backing layer of a
thermo-formable resinous material. The resulting
laminate may be extrusion molded to a pre~formed sub-
strate or maybe formed into a three dimensional article
by injection molding with additional resinous material
adhesively compatible with the composition of the backing
z~
layer. Such res;nous material may include various known
polyolefins, vinyl compounds such as polyv;nylchloride,
and othersO
The present laminates are particularly useful in the
instance where automotive products For exterior exposure
are prepared,as the combined inertrless of the adhesive
and the ultra-violet resistance of both the adhesive and
the capping layer, substantially extend the useful life
of the laminate surface, to resist ultra-violet radiation,
chemical attack from the environment, and resistance to
fracture from mechan;cal impact. The presence of the
catalyst in the adhesive of the present laminate, promotes
the formation of a firm bond between the capping~layer and
the underly;ng base layer, that res;sts surface defect
~ormation and delamination during subsequent thermo-forming
operations, ~nd provides improved transparency that enhances
the brillian~e and reflectivity of the metal layer,
Finallyg the provision of the sandwich of metallized sur-
faces surrounding the base layer, totally eliminates the
"rainbow" effect that can result from the deformation of
the base layer during thermo-forming, as the two layers
cooperate to provide a continuous surfaee regardless of
~he extent to which the base layer may be deformed in
susequent manufacturing procedures.
The present product is easily and inexpensively prepared
w;thout resorting to rigorous processing. Product uniformity
is substantially improved so that the reject rate for formed
parts drops well within commercially acceptable tolerances.
L2~8~
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Accordingly, it ;s a principal object of the present in-
vention to provide a decorat-ive metallized laminate ex-
hibiting improved brilliance, reflectance and wea~herability,
that is capable oF successfully underyoing thermo-forming
operations.
It is a yet Further object of the present invention to
provide a laminate as aforesaid, which eliminates the
frequency of surface defects, loss of reflectance and break-
down of the metal layer upon exposure to ultra-violet light.
It is a yet further object of the present invention to pro-
vide a laminate as aforesaid that is particularly useful
for the forma~ion of exterior automotive parts.
It is a yet further object of the present invention to
provide a method for preparing a bright, metallized laminate,
that is simply and inexpensively practiced without resorting
to rigorous conditions.
It is a yet further object of the present invention to
provide a method as aforesaid, forms a laminate product
capable of successfully undergoing subsequent thermo-forming
operation.
Other objects and advantages will become apparent to those
skilled in the art from a consideration of the ensuing
description, which proceeds with reference to the following
illustrative drawings.
6~
g
BRIEF DESCRIPTION OF DRAWINGS
FIGURE 1 is a schematic fragmentary sectional view of
a laminatein accordance with the present ;nvention.
FIGURE 2 is a schematic representation of the process of
the present invention.
FIGURE 3 is a schematic representation illustrating
the state of preparation of the lam;nate at the various
po;nts of the process illustrated schematically in Figure
2.
FIGURE 4 is a schematic perspective illustrating~a
typical automotive product utilizing the laminate of the
present invention.
DETAILED DESCRIPTION
Referring to Figure 1, the decorative laminate 10 is
illustrated schematically and comprises a base layer 12
that is prepared from a thermo formabte resin film. The
base layer 12 is preferably prepared from a non-oriented
~ilm selected from the group consisting of amorphous
polyester resins, polycarbonate resins, substituted and
unsubstituted vinyl polymers? and their copolymers. More
particularly, the amphorous polyesters may include poly-
ethylene terephthalate, the polycarbonates may include
acrylonitrile-butadiene-styrene resins, the vinyl polymers
may include polyvinylchloride homo- or copolymers as well
as other commercially available vacuum formable or thermo-
formable materials.
- 1 0 -
A preferred material for base layer 12 comprises a poly-
- ethylene terephthalate sold by Allied Chemical Corporation,
known as "Petra". The invention however is not lirnited to
this later material, so long as the base layer is sub
stantially non-oriented, that is to say, has not been
previously mechanically treated, to enhance riy;dity and
"memory".
Base layer 12 may be prov;ded in a variety of thicknesses,
depending upon the specific application for the resulting
laminate~ however, in the instance where an automotive
laminate is contemplated, that is to be formed by injection
molding as described hereinafter, base layer 12 preferably
possesses a thickness ranging from about 3 mils to about
8 milsj. and more specifically made be utilized at a thick-
ness of 5 mils
Base layer 12 is provided on both of its surfaces with
tightly adherent, reflective metal coatings 14 and 16.
While metal coatings 14 and 16 may be applied by a variety
of well recognized techniques, it is preferable in the
present invention that metal coatings 14 and 16 be applied
by vapor deposition. The techniques of vapor deposition,
particularly as utilized in connection with the preparation
of aluminized polyes~er films, are well known, and are des-
cribed, for example, in the Modern Plastics Encyclopedia
(1970--1971), at pages 710 and ~ollowingO For example, in
the instance where aluminum is to be vapor deposited upon
base layer 12, the aluminum (99 * % pure) is held in a
heated crucible in the form of pellets or the like, and is
thereafter vaporized in a high vacuum chamber by resistance
or induction hea~ing. Preferably, base layer 12 comprises
a continuous film~ the running length of which is passed
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through the chamber so that one surface of the film is
exposed to contact with the vaporized metal at a running
rate suffic;ent to deposit a uniform laYer of the ~etal
onto the film, to a thickness of from 100 to Z00 Angstroms.
Simultaneously, the opposite side of the film may be sub-
jected to cooling by contact with a cool;ng cylinder,
to effect the condensation of the aluminum on the metallized
surface. Both of the metal coatings 1~ and 16 may be
prepared by the foregoing method, to the thicknesses spec-
ified above, in accordance with one embodiment hereof.
The provision of metal coa,tings 14 and 16 on both broadsurfaces of base layer 12, forms a sandwiching relation-
ship therewith that obscures visual dîstortion that fre-
quently results when base 12 is subjected to subsequent
deformation by thermo forming techniques. Metal layers
14 and 16 are applied in a particular sequence, that will
be d;scussed later on with reference to the method of
the present invention.
Referring again to Figure l, an outer protective capping
layer 1~ is provided, adhesively bonded to base layer 12,
against metal coating 14. The exact sequence of application
of capping layer 18 will be discussed later on with respect
to ~he present method.
Capping layer 18 is prepared from a film that is treated
to resist attack to ultra-violet light, and to be receptive
to adhesive bonding. In particular, capping layer 18 may
receive surface treatments in a variety of ways, within the
skill of the art , to provide both properties, such as, by
corona discharge treatment, or by the application of known
~2~
~12-
ultra-violet inhibitors and the l;ke D In the ins~ance
where ultra-violet resistance is imparted by the appli-
cation of a coating composition, a varlety of ultra-violet
inhibitors and stabiliz~rs may be utilized, among them com-
pounds containing a benzotriazole or benzophenone nucleus.
These materials are well known and commercially available,
an~ may be selected for use in accor~ance w;th the skill of
the art.
Capping layer 18 itself comprises a resin having parti-
cular resistance to ultra-violet radiation, and the corres-
ponding capability to successfully undergo a ther~o-for~l~ing
operation. Layer 18 may thus be prepared from a material
selected from the group consisting of fluorinated vinyl-
polymers~ fluorinated polyolefins, and polyesters treated
for resistance to ultra-violet radiation. In particular,
capping layer 18 may comprise a polyvinylfluoride, gen-
erally available and manufactured by DuPont under the name
"Tedlar". The capping layer 18 may range in thickness
from 1 to 2 mils, as it is provided to present a uniform
and protective exterior surface to laminate 10.
Capping layer 18 ;s adhesively bonded to metal coating 14
by a pressure and heat sensitive elastomeric adhesive
coating 20. Adhesive coating 20 is resistant to attack by
ultra-violet radiation and is ^harmless with respect to
metal coating 14,and thus possesses favorable qualities
lacking in the adhesives utilized in the prior art. As noted
earlier, prior art adhesives tend to attack the metal layer
and to cause its deterioration, and, by virtue of their in-
stability in contact with ultra-violet light, tend to
deteriorate unilaterally, and to allow delamination and
6~3~
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other surface discontinuities to appear in the laminate
over a short period of time. The adhesive coating 20 may
be a composition such as a silicone resin or an appropriate
acryl;c polymer, and is preferably the former. In parti-
cular, the adhesive coating 20 may comprise homopolymersand copolymers of siloxane resins, such as those commer-
cially manutactured by the General Electr;c Company, and
others.
The compositions of adhesive coating 20, preferably con- -
tain a polymerization catalyst in amount that ranges
from about 2% to about 6% by weight of the adhesive
resin solids. The provision of the catalyst within this
range is particularly advantageous, as it confers a partial
cure to the adhesive that promotes improved bonding and
stability of the adhes;ve after its appl;cation and d;s-
position between capping layer 18 and metal coating 14,
that resists distorti~n and resulting surface discont~
inuities during subsequent thermo-forming operations. One
of the problems that has attended the use of various ad-
hesives, particularly in contact with the metal layer ofreflective laminates~ has been the tendency of the adhesive,
not only to attack the metal layer, but to undesirably
migrate during subsequent thermo-forming. The present
adhesive compositions neither attack the metal layer nor
migrate in such manner, and permit the formation of
faithfully uniform,.thermo-formed products, having retained,
improved brilliance and reflectivity.
A variety of polymerization catalysts may be utilized in
the compositions of adhesive coating 20, among them benzoyl
peroxide, substituted benzoyl peroxide, amino-substituted
compounds and silicone compounds. A preferred catalyst
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comprises an amino-substituted silane, such as gamma
aminopropyl triethoxysilane.
Adhesive coating 20 is pre-Ferably applied to the surface
of capping layer 1~ that is to be bonded to metal coating
14, prior to the bonding thereof. The exact procedure
associated with the application oF adhesive coatiny 20,
will be discussed w;th reference to the method of the pre-
sent invention, later on. Preferably, adhesive coating
20 is applied to a dry thickness ranging from about .3
mils to about .8 mils, and particularly may be app'lied
to a thickness ranging from .35 mils to .4 mils.
As noted earlier, metal coatings 14 and 16 may~be prepared
from a variety o~ metals well known for imparting highly
reflective corrosion and abrasion resistant surfaces.
'Ln particular, such metals may comprise chromium, alloys
o~ chromium, nickel, nickel and chromium alloys such as
Nichrome, iron, alloys of iron and chromium, stainless
stee7, aluminum, alloys of aluminum and others. Pre-
ferably, and as indicated earlier, the metal applied toform metal coatings 14 and 16 comprises aluminum.
Referring again to Figure 1, laminate 10 is illustrated
therein with a backing layer 22, that is laminated by
conventional techniques to the free surface of coating 16.
2~ Backing layer 22 may be prepared as a sheet or the like from
a variety o~ resins, including various polyolefins, vinyl poly-
mers and copolymers, polycarbonates, acry'lic polymers and co-
polymers, and other materials capable of undergoing a thermo-
forming operation. In particular, backing làyer~22 may be
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prepared from polyvinylchloride homo--and co-polymers,
polyethylene, i.ts copolymers and interpolymers, acrylon-
itrile-butadiene-styrene .copolymers, and suitable mix-
tures thereof. Preferably, backing layer 22 comprises
5 an ion-linked and modified ethylene interpoloymer, known
` commercially as "Surlyn"~
Backing layer 22 may vary ;n th;ckness, and, for example,
may have a thickness of 20 mils, when provided for
thermo-forming and subsequent injection molding for ex-
terior automot;ve application. In such ins-tances, additional
resinous material, either identical to or variant but
compatible with the composition of backing layer 22--may be
laminated to the free surface thereof, or injection
molded into association therewith by processes described
15 further, later on.
In accordance w;th a further embodiment of the present
inventiong a method for preparing the present laminates
is disclosed, which comprises first applying a metal
coating on one surface of base layer 12~ adhesively bonding
capping layer 18 to the metallized surface provided, for
exampleg by metal coating 14, and thereafter applying a
second metal coating 16 to the uncoated free surface of
base layer 12. As noted above, the resulting laminate 10
may opt~onally include a backing layer 22 that is sub-
25 sequently appl;ed by lam;nat;on techniques known in theart, including extrusion lamination, and the like~
The present method will be better understood from a re-
view of Figure 2,.comprising a schematic representation of
the important manufacturing steps. Initially,
~L2~i8~n
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the first step of the present method, not shown in Figure
2, however, comprises the deposition of metal coating 14
on one surface of base layer 12. Preferably, base layer
12 is disposed in an extended strip of varying widths,
maintained on a roll, and is continually fed through a
vacuum deposition chamber, in the manner described earlier,
to provide a metallized surface on one side of the film
strip. After metallization is completed, the one-sided
metallized strip of base layer 12 is gathered by a
take up reel, not shown, and is stored in this condition
for further processing in accordance herewith. The fore-
going treatment is performed in accordance with well
known conventional industry standards, and a specific
illustration thereof is not believed to be necessary.
The next step comprises application of adhesive coating 20
to one surface of the film defining capping layer 18. As
shown in Figure 2, capping layer 18 may be paid out from
a continuous roll 24 to provide a strip of material for
continuous adhesive coating. Capping layer 18 then
passes through an adhesive coater where a regulated amount
of adhesive composition is applied to the lower surface
of layer 18, such as, for example, by the schematic assem-
bly 26 illustrated herewith. ~n particular, ass~mbly 26
may comprise a trough having a quantity of adhesive com-
positions therein, a dip roll 30 that initially picks upthe adhesive composition and relays it to a transfer roll
32, for application to the surface of cappin~ layer 18.
Proper coating pressure maybe provided by a squeeze roll
34, so that a uniform coat;ng 20 results. Thereafter,
the coated layer 18 maybe exposed to heat to dry adhesive
coating 20, by passage through a drying tunnel 36, where
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heat is applied by forced air impjnging on the wet sur-
face. Drying may take place at a temperature on the
order nf about 240F with the coated layer 18 travelling
at a speed of~ ~or example, 70 feet per minute. Naturally,
the Foregoing parameters are illustrative only. The
resulting composite layer 38 is now ready for further
processing in accordance with the present method.
The next step in the process comprises the adhesive bonding
of composite capping layer 38 with the base layer 12
previously coated on one side with a metal coating such
as metal coating 14. As noted earlierg the application
~f coating 14 is conventional and is not illustrated
schematically herein. Accordingly, a pay out reel 40
bearing the base layer 12 having the first metal coating
14 thereon, hereinafter referred to as first composite
base layer 42 is brought into contact with the adhesive
coated surface of composite cappinq laver 38, with its
metal coated surface disposed thereagainst, At this
point, adhesive coating 20 is dry, however, the bonding
of coating 14 to coating 20 may take p~ace under pressure
alone, as coating 20, noted earlier~ is pressure sensitive.
Alternatively, bonding may take place under combined heat
and pressure, and these latter conditions are preferred.
As illustrated in Figure 2, composite layers 38 and 42
maybe bonded by passage betwe~n pressure rollers 44 and
46, which may likewise be heated to impart both heat and
pr~ssure to the mater;als. For example, bonding may take
place at temperatures ranging from about 140 to 150F,
and pressures ranging from about 30 to about 60 psi.
Naturally, the foregoing parameters are illustrative only.
-18-
After ex;ting trom pressure rollers 44 and 46, the resulting
capped, metallized base ~8 consists essentially of four
discrete layers, namely, capping layer l~, adhesive coat1ng
20, metal coating 14 and base layer 12. Metallized base
4~ is thereafter coated on the free surface of base layer
12, with a second reflective metal coating 16, by feeding
base ~8 through a conventional vacuum metalization cham-
ber schematically illustrated at 50. As illustrated in
Figure 2 and described earlier, a quantity of metal in
pelletized form w;thin a conta;ner such as crucible 52,
is heated, such as by inductive heating means 54 to
cause a fine layer of metal to deposit on the adjacent
side of base 48, whereby layer 16 is formed. Layer 16
like layer 14, maybe formed to a thickness of from lOO to
200 Angstroms, and the resulting product emerging from
chamber 50 will comprise the preliminary laminated structure
56 that is the essence of the present inventionO Optionally,
as illustrated herein and discussed earlier, a backing layer
22 disposed on a similar pay out reel 58 may be bonded to
the ~ree surface of metal coating 16, of laminated structure
56, by conventional techniques9 including9 as illustrated,
passage through heated pressure rollers 60 and 62. While
bonding by heat and pressure is illustrated schematically
herein, it is to be understood, as discussed earlier,
that the bonding of backing layer 22 to laminated structure
56 may be performed by other l-aminating techniques known
in the art, with;n the scope of the present invention.
The product exiting from rollers 60 and 62 comprises
laminate lO, illustrated in Figure l.
Referring briefly to Figure 3, a schematic cross-sectional
illustration of the various layers coated and otherwise
-1 9-
combined in accordance with the present method is pro-
vided, to illustrate the manner in which the respective
layers are accumulated and brollght together. Thus, the
left hand portion of the figure shows capping layer 18
both before and after application of adhesive coating 20,
and the resulting composite capping layer 38 produced
thereby. Likewise, first composite base layer ~2 and
its components, metal coating 14 and base layer 12 are
illustrated being brought together with composite capping
layer 38, to form the multi-layered capped, metallized
base 48. In turn, metallized base 48 is shown after
vacuum deposition of metal coating 16 on the free surface
of base layer 12, to form preliminary laminated structure
56, and the final laminate 10 is shown to result~from
the bonding of backing layer 22 to the free surface of
metal coating 16.
As noted earlier, the laminate produced in accordance with
the present invention is particularly useful for auto-
motive applications, where deformation of the reflective
surface is frequently necessary to form multiple con-
toured products for trim and bumper applications. Re-
ferring now to Figure 4, a representative automotive
end product is illustrated in schematic cross-section,
prepared from laminate 10. Thus, bumper panel 64 com-
prises a segment of laminate lD that has been heated andmolded by thermo forming techniques, to assume the three
dimensional, curved shaped illustrated. The thermo forming
operation per se, does not form a part of the present in-
vention, and is accordingly not illustrated hereîn.
lZ~ ;8~.
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Generally, a précut segment of laminate 10, of a size
sufFicient to form the contoured part illustrated in
Figure 4, is placed in a heated die cavity, where either
heat and vacuum or die pressure forces the laminate 10
to assume the configuration illustrated. Thereafter,
the formed laminate maybe placed in an injection molding
cavity, where it serves as one of the surfaces against
which a quantity of moldable resin is injected, in
accordance with known techniques and parameters. After
the sufficient resin has been injected, the molded
article is permitted to cool and solidify. Thereafter,
the male mold segment is retracted, and the excess material
from the article is trimmed and removed. Finally, the injection
molded article is removed from the female die, and the formation
of the product such as bumper panel 64 is complete.
Referring further to Figure 4, panel 64 is illustrated with
a line of demarcation between backing layer 22 and the resinous
substrate 66, to emphasize the quantity of resin that is
frequently added by the final injection molding of the article.
Naturally, the amount of resin utilized in the addition of
substrate 66 may vary in accordance with manufacturing re~uire-
ments and specific applications, and the present invention is
not to be construed by way of limitation to the present illus-
trations.
The present laminate and associated method of preparation may
be utilized for ~he production of a variety of products, in-
cluding, without limitation, the preparation of a transfer
sheet comprising a conventional carrier having a release coat-
ing disposed thereon, to which the outer surface of capping
layer 18 may be releasably boundO In such instance, the trans-
fer sheet would preferably comprise the preliminary laminated
structure 56, identified in Figure 3, which might optionally
bear an appropriate adhesive coating, not shown hereina on the
2~
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free metallized surface of metal coating 16. Naturally, the
foregoing is illustrative of a variant embodiment and utility
of the present invention.
This invention may be embodied in other forms or carried out
in other ways without departing from the spirit or essential
characteristics thereof~ The present d;sclosure is therefore to
be considered as in all respects illustrative and not restrictive,
the scope of the invention being indicated by the appended claims,
and all changes which come within the meaning and range of equiv-
alency are intended to be embraced therein.
