Method of applying painted carrier films to automobile body parts

Claim 1

A method of making paint coated parts each comprising a stretched facing sheet layer and an underlying substrate layer, said method comprising the steps of: providing a facing sheet layer having a top surface and a bottom surface wherein said top surface is first painted to a predetermined color by a color coat formulation containing flakes and then coated with at least one layer of a clear coat such that the total clear coat thickness is no less than 15 microns, curing said color coat and said at least one layer of clear coat, heating said facing sheet to a temperature at which said sheet becomes sufficiently pliable and stretchable for vacuum forming, positioning said heating facing sheet over said substrate, introducing a layer of an adhesive between said heated facing sheet and said substrate layer before contacting said facing sheet with said substrate, and drawing vacuum from under said substrate layer such that said facing sheet stretches to a strain of at least 10% under said vacuum, and conforms and adheres to said substrate in such a way that said clear coat layer retains the gloss appearance of said facing sheet at a gloss reading of at least 50 as measured by a Gardner 20° gloss meter.

Claim 2

A method of making paint coated parts each comprising a stretched facing sheet layer and an underlying substrate layer, said method comprising the steps of: providing a facing sheet layer having a top surface and a bottom surface wherein said top surface is first painted to a predetermined color by a color coat formulation containing flakes and then coated with at least one layer of a clear coat such that the total clear coat thickness is no less than 15 microns, curing said color coat and said at least one layer of clear coat, heating said facing sheet to a temperature at which said sheet becomes sufficiently pliable and stretchable for vacuum forming, positioning said heating facing sheet over said substrate, introducing a layer of an adhesive between said heated facing sheet and said substrate layer before contacting said facing sheet with said substrate, and drawing vacuum from under said substrate layer such that said facing sheet stretches to a strain of at least 10% under said vacuum, and conforms and adheres to said substrate in such a way that said clear coat layer retains the gloss appearance of said facing sheet at a gloss reading of at least 50 as measured by a Gardner 20° gloss meter.

Claim 3

A method of making paint coated automobile parts each comprising a stretched facing sheet layer and an underlying substrate layer, said method comprising the steps of: providing a facing sheet layer having a top surface and a bottom surface wherein the top surface is first painted to a predetermined color by a color coat formulation containing flakes and then coated with at least one layer of clear coat such that the total clear coat thickness is no less than 15 microns and said bottom surface is coated with a layer of adhesive, curing said color coat and said at least one layer of clear coat, heating said facing sheet to a temperature at which said sheet becomes sufficiently pliable and stretchable for vacuum forming, positioning said heated facing sheet over said substrate, drawing vacuum from under said substrate layer such that said facing sheet stretches to a strain of at least 10% under said vacuum and conforms and adheres to said substrate in such a away that said clear coat layer retains the gloss appearance of said facing sheet at a gloss reading of at least 50 as measured by a Gardner 20° gloss meter.

Claim 4

A method of making paint coated automobile parts each comprising a stretched facing sheet layer and an underlying substrate layer, said method comprising the steps of: providing a facing sheet layer having a top surface and a bottom surface wherein the top surface is first painted to a predetermined color by a color coat formulation containing flakes and then coated with at least one layer of clear coat such that the total clear coat thickness is no less than 15 microns and said bottom surface is coated with a layer of adhesive, curing said color coat and said at least one layer of clear coat, heating said facing sheet to a temperature at which said sheet becomes sufficiently pliable and stretchable for vacuum forming, positioning said heated facing sheet over said substrate, drawing vacuum from under said substrate layer such that said facing sheet stretches to a strain of at least 10% under said vacuum and conforms and adheres to said substrate in such a away that said clear coat layer retains the gloss appearance of said facing sheet at a gloss reading of at least 50 as measured by a Gardner 20° gloss meter.

Claim 5

A method of making paint coated parts each comprising a stretched facing sheet layer and an underlying substrate layer, said method comprising: providing a facing sheet layer having a top surface and a bottom surface wherein said top surface is painted to a predetermined color with a color coat formulation containing flakes and then coated with at least one layer of a clear coat such that the total clear coat thickness is between 20 to 180 microns, curing said color coat and said at least one layer of clear coat, heating said facing sheet to a temperature at which said sheet becomes sufficiently pliable and stretchable for vacuum forming, positioning said heated facing sheet over said substrate, introducing a layer of an adhesive between said heated facing sheet and said substrate layer before contacting said facing sheet with said substrate, drawing vacuum from under said substrate layer such that said facing sheet stretches under said vacuum at one or more predetermined locations to a strain of up to 100%, conforming and adhering said stretched facing sheet to said substrate in such a way that said clear coat layer retains the gloss appearance of said facing sheet at a gloss reading of at least 50 as measured by a Gardner 20° gloss meter.

Claim 6

A method of making paint coated parts each comprising a stretched facing sheet layer and an underlying substrate layer, said method comprising: providing a facing sheet layer having a top surface and a bottom surface wherein said top surface is painted to a predetermined color with a color coat formulation containing flakes and then coated with at least one layer of a clear coat such that the total clear coat thickness is between 20 to 180 microns, curing said color coat and said at least one layer of clear coat, heating said facing sheet to a temperature at which said sheet becomes sufficiently pliable and stretchable for vacuum forming, positioning said heated facing sheet over said substrate, introducing a layer of an adhesive between said heated facing sheet and said substrate layer before contacting said facing sheet with said substrate, drawing vacuum from under said substrate layer such that said facing sheet stretches under said vacuum at one or more predetermined locations to a strain of up to 100%, conforming and adhering said stretched facing sheet to said substrate in such a way that said clear coat layer retains the gloss appearance of said facing sheet at a gloss reading of at least 50 as measured by a Gardner 20° gloss meter.

Claim 7

A method of making paint coated parts each comprising a stretched facing sheet layer and an underlying substrate layer, said method comprising: providing a facing sheet layer having a top surface and a bottom surface wherein said top surface is painted to a predetermined color with a color coat formulation containing flakes and then coated with at least one layer of a clear coat such that the total clear coat thickness is between 20 to 180 microns and said bottom surface is coated with a layer of adhesive, curing said color coat and said at least one layer of clear coat, heating said facing sheet to a temperature at which said sheet becomes sufficiently pliable and stretchable for vacuum forming, positioning said heated facing sheet over said substrate, and drawing vacuum from under said substrate layer such that said facing sheet stretches under said vacuum at one or more predetermined locations to a strain of up to 100%, conforming and adhering said stretched facing sheet to said substrate in such a way that said clear coat layer retains the gloss appearance of said facing sheet at a gloss reading of at least 50 as measured by a Gardner 20° gloss meter.

Claim 8

A method of making paint coated parts each comprising a stretched facing sheet layer and an underlying substrate layer, said method comprising: providing a facing sheet layer having a top surface and a bottom surface wherein said top surface is painted to a predetermined color with a color coat formulation containing flakes and then coated with at least one layer of a clear coat such that the total clear coat thickness is between 20 to 180 microns and said bottom surface is coated with a layer of adhesive, curing said color coat and said at least one layer of clear coat, heating said facing sheet to a temperature at which said sheet becomes sufficiently pliable and stretchable for vacuum forming, positioning said heated facing sheet over said substrate, and drawing vacuum from under said substrate layer such that said facing sheet stretches under said vacuum at one or more predetermined locations to a strain of up to 100%, conforming and adhering said stretched facing sheet to said substrate in such a way that said clear coat layer retains the gloss appearance of said facing sheet at a gloss reading of at least 50 as measured by a Gardner 20° gloss meter.

Claim 9

A method of making paint coated parts each comprising a stretched facing sheet layer and an underlying substrate layer, said method comprising: providing a facing sheet layer having a top surface and a bottom surface wherein said top surface is first painted to a predetermined color with a color coat formulation containing flakes and then coated with at least one layer of a clear coat such that the total clear coat thickness is between 15 to 150 microns, curing said color coat and said at least one layer of clear coat, heating said facing sheet to a temperature at which said sheet becomes sufficiently pliable and stretchable for vacuum forming, positioning said heated facing sheet over said substrate, introducing a layer of an adhesive between said heated facing sheet and said substrate layer before contacting said facing sheet with said substrate, drawing vacuum from under said substrate layer such that said facing sheet stretches to a strain of up to 25% at one or more predetermined locations under said vacuum and conforms and adheres to said substrate in such a way that said clear coat layer retains the gloss appearance of said facing sheet at a gloss reading of at least 50 as measured by a Gardner 20° gloss meter.

Claim 10

A method of making paint coated parts each comprising a stretched facing sheet layer and an underlying substrate layer, said method comprising: providing a facing sheet layer having a top surface and a bottom surface wherein said top surface is first painted to a predetermined color with a color coat formulation containing flakes and then coated with at least one layer of a clear coat such that the total clear coat thickness is between 15 to 150 microns, curing said color coat and said at least one layer of clear coat, heating said facing sheet to a temperature at which said sheet becomes sufficiently pliable and stretchable for vacuum forming, positioning said heated facing sheet over said substrate, introducing a layer of an adhesive between said heated facing sheet and said substrate layer before contacting said facing sheet with said substrate, drawing vacuum from under said substrate layer such that said facing sheet stretches to a strain of up to 25% at one or more predetermined locations under said vacuum and conforms and adheres to said substrate in such a way that said clear coat layer retains the gloss appearance of said facing sheet at a gloss reading of at least 50 as measured by a Gardner 20° gloss meter.

Claim 11

A method of making paint coated parts each comprising a stretched facing sheet layer and an underlying substrate layer, said method comprising: providing a facing sheet layer having a top surface and a bottom surface wherein said top surface is first painted to a predetermined color with a color coat formulation containing flakes and then coated with at least one layer of clear coat such that the total clear coat thickness is between 15 to 150 microns and said bottom surface is coated with a layer of adhesive, curing said color coat and said at least one layer of clear coat, heating said facing sheet to a temperature at which said sheet becomes sufficiently pliable and stretchable for vacuum forming, positioning said heated facing sheet over said substrate, and drawing vacuum from under said substrate layer such that said facing sheet stretches to a strain of up to 25% at one or more predetermined locations under said vacuum and conforms and adheres to said substrate in such a way that said clear coat layer retains the gloss appearance of said facing sheet at a gloss reading of at least 50 as measured by a Gardner 20° gloss meter.

Claim 12

A method of making paint coated parts each comprising a stretched facing sheet layer and an underlying substrate layer, said method comprising: providing a facing sheet layer having a top surface and a bottom surface wherein said top surface is first painted to a predetermined color with a color coat formulation containing flakes and then coated with at least one layer of clear coat such that the total clear coat thickness is between 15 to 150 microns and said bottom surface is coated with a layer of adhesive, curing said color coat and said at least one layer of clear coat, heating said facing sheet to a temperature at which said sheet becomes sufficiently pliable and stretchable for vacuum forming, positioning said heated facing sheet over said substrate, and drawing vacuum from under said substrate layer such that said facing sheet stretches to a strain of up to 25% at one or more predetermined locations under said vacuum and conforms and adheres to said substrate in such a way that said clear coat layer retains the gloss appearance of said facing sheet at a gloss reading of at least 50 as measured by a Gardner 20° gloss meter.