US4902557A — Thermoplastic polyolefin composite structure

Claim 1

Independent Claim 304 words

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 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 to 2. 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 to 3. 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.

Claim 2

Dependent Claim 304 words

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 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 to 2. 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 to 3. 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.

Claim 3

Dependent Claim 23 words

The composite of claim 1 in which the chlorinated polyolefin consists essentially of a propylene/maleic acid copolymer containing about 15-50% by weight chlorine.

Claim 4

Dependent Claim 22 words

The composite of claim 1 in which the chlorinated polyolefin consists essentially of a chlorinated polyethylene containing about 15-50% by weight chlorine.

Claim 5

Dependent Claim 26 words

The composite of claim 1 in which the size layer consists essentially of a chlorinated polypropylene and maleic anhydride polymer containing about 18-35% by weight chlorine.

Claim 6

Dependent Claim 40 words

The composite of claim 1 in which the size layer of the chlorinated polyolefin comprises a mixture of the chlorinated polyolefin and a thermoplastic polymer selected from the group consisting of ethylene vinyl acetate polymer, alkyd resin, and acrylic polymers.

Claim 7

Dependent Claim 28 words

The composite of claim 1 in which the clear layer comprises a layer of a polymer selected from the group consisting of methyl methacrylate polymer and copolymers thereof.

Claim 8

Dependent Claim 51 words

The composite of claim 1 in which the clear layer comprises polymethyl methacrylate and a graft copolymer having a backbone of polymerized monomers of esters of acrylic acid or methacrylic acid and allyl methacrylate or allyl acrylate grafting sites having grafted thereto polymeric segments of alkyl acrylate or alkyl methacrylate units.

Claim 9

Dependent Claim 65 words

The composite of claim 7 in which the pigment containing layer comprises polymethyl methacrylate and a graft copolymer having a backbone of polymerized monomers of ester of acrylic acid or methacrylic acid and allyl methacrylate or allyl acrylate grafting sites having grafted thereto polymeric segments of alkyl acrylate or alkyl methacrylate units and contains pigment in a pigment to binder weight ratio of about 1/100-100/100.

Claim 10

Dependent Claim 42 words

The composite of claim 1 in which the pigment containing layer comprises a layer of a polymer selected from the group consisting of methyl methacrylate polymer and copolymers thereof and contains pigment in a pigment to binder weight ratio of about 1/100-100/100.

Claim 11

Dependent Claim 31 words

The composite of claim 1 in which the clear composite a mixture of about 50-80% by weight of polyvinylidene fluoride and correspondingly 50-20% by weight of polymethyl methacrylate or polyethyl methacrylate.

Claim 12

Dependent Claim 46 words

The composite of claim 10 in which the pigment containing paint layer comprises a mixture of about 50-80% by weight of polyvinylidine fluoride and correspondingly 50-20% by weight of polymethyl methacrylate or polyethyl methacrylate and pigment in a pigment to binder weight ratio of about 1/100-100/100.

Claim 13

Dependent Claim 30 words

The composite of claim 1 in which the flexible sheet of thermoplastic polyolefin comprises an extruded sheet of a compounded mixture of polypropylene, a synthetic elastomeric resin, pigments and additives.

Claim 14

Dependent Claim 26 words

The composite of claim 1 in which the rigid layer of thermoplastic polyolefin comprises a compounded mixture of polypropylene, a synthetic elastomeric resin, pigments and additives.

Claim 15

Dependent Claim 184 words

A thermoformable sheet structure useful for forming the composite of claim 1 consisting essentially of the following components: 1. a multilayer coating consisting essentially of a. a 10-125 micron layer 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 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 coating being firmly bonded by lamination to 2. a 250-1250 thick layer of 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 sheet.

Claim 16

Dependent Claim 19 words

The thermoformable sheet structure of claim 14 in which the chlorinated polyolefin consists essentially of a propylene/maleic acid copolymer.

Claim 17

Dependent Claim 17 words

The thermoformable sheet structure of claim 14 in which the chlorinated polyolefin consists essentially of chlorinated polyethylene.

Claim 18

Dependent Claim 28 words

The thermoformable sheet structure of claim 14 in which the size layer consists essentially of a chlorinated polypropylene and maleic anhydride polymer containing about 18-35% by weight chlorine.

Claim 19

Dependent Claim 38 words

The thermoformable sheet structure of claim 14 in which the size layer of the chlorinated polyolefin comprises a mixture containing a thermoplastic polymer selected from the group consisting of ethylene vinyl acetate polymer, alkyd resin, and acrylic polymers.

Claim 20

Dependent Claim 30 words

The thermoformable sheet structure of claim 14 in which the clear layer comprises a layer of a polymer selected from the group consisting of methyl methacrylate polymer and copolymers thereof.

Claim 21

Dependent Claim 53 words

The thermoformable sheet structure of claim 14 in which the clear layer comprises polymethyl methacrylate and a graft copolymer having a backbone of polymerized monomers of ester of acrylic acid or methacrylic acid and allyl methacrylate of allyl acrylate grafting sites having grafted thereto polymeric segments of alkyl acrylate of alkyl methacrylate units.

Claim 22

Dependent Claim 44 words

The thermoformable sheet structure of claim 14 in which the pigment containing layer comprises a layer of a polymer selected from the group consisting of methyl methacrylate polymer and copolymers thereof and contains pigment in a pigment to binder weight ratio or about 1/100-100/100.

Claim 23

Dependent Claim 67 words

The thermoformable sheet structure of claim 14 in which the pigment containing layer comprises polymethyl methacrylate and a graft copolymer having a backbone of polymerized monomers of ester of acrylic acid or methacrylic acid and allyl methacrylate or allyl acrylate grafting sites having grafted thereto polymeric segments of alkyl acrylate or alkyl methacrylate units and contains pigment in a pigment to binder weight ratio of about 1/100-100/100.

Claim 24

Dependent Claim 29 words

The thermoformable sheet structure of claim 14 in which the clear comprises a mixture of about 50-80% by weight of polyvinylidine fluoride and correspondingly 50-20by weight of polymethyl methacrylate.

Claim 25

Dependent Claim 45 words

The thermoformable sheet structure of claim 14 in which the pigment containing paint layer comprises a mixture of about 50-80% by weight of polyvinylidene fluoride and correspondingly 50-20% by weight of polymethyl methacrylate and pigment in a pigment to binder weight ratio of about 1/100-100/100.

Claim 26

Dependent Claim 32 words

The thermoformable sheet structure of claim 14 in which the flexible sheet of thermoplastic polyolefin comprises an extruded sheet of a compounded mixture of polypropylene, a synthetic elastomeric resin, pigments and additives.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1993-02-19	1993-08-21	1994-02-20	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1997-02-19	1997-08-21	1998-02-20	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2001-02-19	2001-08-21	2002-02-20	$7700.00	Window Closed / Lapsed

Thermoplastic polyolefin composite structure

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