WO2000035652A1 - Automotive trim with clear top coat and method of making same - Google Patents

Abstract

An exterior automotive trim product, and method of making the same. In certain embodiments, a color pigmented thermoplastic layer (75) is provided. A transparent clear coat (77) is calendared to the color pigmented layer (75) to form a composite or laminate. The laminate is subsequently vacuum-formed into a three dimensional shape approximating the desired shape of a final trim product. The vacuum-formed laminate (91) is then inserted into an injection molding device, and semi-molten resin (119) injected into the mold cavity behind the laminate (91). The resin fuses with the vacuum-formed laminate (91) with the result being the final automotive trim product. Thus, no spray painting or spraying of solvents is required, and burdensome dry paint transfer techniques may be avoided.

Description

AUTOMOTIVE TRIM WITH CLEAR TOP COAT AND METHOD OF MAKING SAME

This invention relates to trim components for

automobiles and similar vehicles, as well as to methods

of making same. More particularly, this invention

relates to exterior components of such vehicles which are

provided for either appearance purposes or are of a size

and shape to make a visual contribution to the exterior

appearance of a vehicle.

BACKGROUND OF THE INVENTION

It is known to apply automotive trim pieces to the

exterior of wheeled vehicles such as cars and trucks.

Examples of such trim include accent stripes, side door

bumper elements, claddings, wheel covers, grills, and

bumper fascia. The instant invention further applies to

exterior vehicle components which have previously been

made of plastic materials, such as door sides and the

like.

In the prior art, exterior molded automotive trim

components are typically painted in order to provide them

with color. It is desirable that the paint color be

compatible with the appearance of the vehicle (e.g. the same as that of the vehicle, or complimentary thereto) .

Following painting of a molded piece of trim, a clear

coat is often sprayed over the paint to give it luster.

Prior to painting molded trim, it has often been

necessary to prepare the exterior surfaces of such

components by applying a primer which promotes adhesion

of the paint to the surface of the molded component .

After the paint is applied over the primer by spraying,

the color appearance of the final product results from

the pigmentation of the paint layer which is sandwiched

between the sprayed-on clear coat and the underlying

primer.

Unfortunately, spray painting of molded components

for use on vehicles is often undesirable due to the

potential for resulting paint lines, a need for masking

tape, and the corresponding labor involved. Moreover,

spray painting is undesirable due to the high capital

equipment cost associated with paint line equipment, and

potentially hazardous environmental issues relating to

required solvents and the like. Thus, it will be

apparent to those of skill in the art that it would be

desirable if automotive trim components could be

manufactured in a manner so that they were color compatible with automotive exteriors, without the need

for spray painting the molded components.

It is also known to manufacture automotive exterior

plastic components simply as a product m the condition

which it comes out of the mold (i.e. without painting) .

For such components, the plastic which is used to

injection mold the component may include color

pigmentation so that the desired color appears not only

on the surface but throughout the molded article.

Unfortunately, the surface of such molded components,

while initially presenting a desirable color, lacks

luster and also can be easily scratched and/or marred to

further detract from its lack of luster.

Molded automotive trim components have numerous

requirements or desires known by automotive

manufacturers It is desirable that such trim components

maintain their form without becoming too soft m hot

weather conditions, or too brittle m cold weather. Such

products should also be capable of holding up and

withstanding exposure to ultraviolet (UV) rays of the

sun. It is also desired that certain components be

capable of a certain amount of flexibility without

permanently deforming or denting. It is desirable that surface appearances of such components exhibit

considerable luster.

Another approach to automotive trim coloring

includes the use of dry paint film. A dry paint-coated

laminate can be utilized to replace conventional spray

paint. The dry laminate is made by applying a paint coat

to a casting sheet by way of conventional paint coating

techniques. The dried paint coat is then transferred

from the casting sheet to a trim panel by way of known

dry paint transfer technology. The laminate may later be

thermo- formed into a three dimensional shape and then

bonded or integrally molded to an underlying plastic car

body member or panel . Such known dry paint film

technology is disclosed, for example, in U.S. Patent No.

5,725,712, the entire disclosure of which is incorporated

herein by reference.

Prior art Figures 1-10 will be referred to for the

purpose of describing conventional dry paint film

technology for application to automotive trim components.

Figure 1 illustrates a conventional automobile, which

includes numerous exterior plastic molded body components

which may be colored. Automobile 1 in Figure 1 includes

bumper fascia 3, wheel covers 5, and many other exterior components which may be made via injection molding

technology.

The '712 patent describes a system for coloring

automotive trim components. The first step in this dry

paint film approach is the provision of the dry laminate

7 of Figure 2. Laminate 7 includes self-supporting

carrier sheet 9 (i.e. casting film), clear coat 11, paint

coat 13, and optional size coat 15 for providing adhesion

to a backing sheet in a subsequent laminating step. In

order to manufacture laminate 7, clear coat 11 is coated

onto carrier 9 by a complicated reverse roll coating

process shown in prior art Figure 3, in which clear coat

lacquer is contained in coating pan 17. Applicator roll

19 picks up lacquer from the pan and coats it onto

carrier film 21 (or 9) after it passes over guide roll

23. After exiting the nip (or die) between applicator

roll 19 and rubber backup roll 25, the coated carrier

film 27 passes to a multiple zone drying oven. The

laminate is dried in the oven at temperatures of from

about 250° - 400° F via a multi-stage drying process.

After drying, a two layered laminate, including carrier 9

and clear coat 11, is provided. Color coat 13 is then bonded to clear coat 11 after

the clear coat has dried on carrier 9. Color paint coat

13 is typically applied to the carrier by reverse roller

coating techniques as shown in Figure 3, with the color

coat being dried by passing it through the multiple

drying zones discussed above in curing the clear coat .

Thus, the complicated reverse rolling techniques and

multi-zone drying ovens of Figure 3 must be utilized on

numerous occasions in order to apply the clear coat and

the color coat to the carrier.

Size coat 15 is next coated onto paint coat 13, and

is typically applied as a thermoplastic and dried in the

same multi-step drying step utilized above for the clear

and color coats. The result is laminate 7 of Fig. 2.

Laminate 7 is next: laminated to a thermo-formable

backing sheet by dry paint transfer laminating techniques

shown in Figure 4, to form laminate 29 of Fig. 5. During

this burdensome laminating step of Fig. 4, paint -coated

laminate 7 is stored on unwind roll 31 and a flexible 20

mil thick ABS backing sheet 33 is stored on unwind roll

35. When rolls 31 and 35 unwind as shown in Figure 4,

and the webs respectively pass over drums 37, paint -

coated laminate 7 and ABS sheet 33 are bonded together between heated laminating drum 39 and roll 41. Laminate

7 is bonded to sheet 33 as the two pass between rolls 39

and 41. The resulting laminate 29 then passes onto

storage drum 43. The result is a roll of the laminate 29

of Fig. 5, including a color determined by the colored

pigment in paint layer 13. Laminate 29 includes backing

sheet 33, size coat 15, color coat 13, and clear coat 11.

Next, laminate 29 is thermo-for ed into a desired

three dimensional shape. Referring to Fig. 6, laminate

29 is placed inside clamping frame 45 of a vacuum- forming

machine. Frame 45 is moved into oven 47 for heating

laminate 29. Backing sheet 33 is heated in oven 47 and

laminate 29 sags as shown at 49. Then, clamping frame 45

is moved back to the position above vacuum- forming buck

51. The preheated laminate 29 is next vacuum- formed into

a desired three dimensional shape by drawing a vacuum on

buck 51 through connection 53 to a vacuum pump, and buck

51 is raised to its Fig. 7 position. Vacuum is pulled

through holes in buck 51 to force the pre-heated plastic

of laminate 29 into the shape of the working surface of

buck 51.

Next, the thermo-formed three dimensionally shaped

laminate 29 is bonded to a substrate panel as shown in Figures 8-9. Laminate 29 is placed into an injection

mold and fused to the face of an injection molded

substrate 55. Fig. 8 shows preformed laminate 29 placed

in the mold cavity between front and rear mold halves 57

and 59. The inside surface 61 of mold half 57 nearly

identically matches the exterior contour of paint -coated

laminate 29. Surface 61 may be a rigid, high gloss,

highly polished surface which is substantially free of

surface defects so that no or few defects are transferred

to the high gloss, clear coated surface of the laminate.

After laminate 29 is in place, semi-molten injection

molding material 55 is injected into the mold through

passage 63 behind pre-formed laminate 29. The molding

material conforms to the shape of the mold cavity and is

permanently fused to backing sheet 33 of laminate 29 in

the mold. A cross-section of the resulting three-

dimensionally molded trim component is shown in Fig. 10.

As can be seen above, dry paint film transfer

technology is very burdensome and complicated. For

example, the aforesaid process illustrated in Figs. 1-10

requires going through rollers and dryers on numerous

occasions, as well as the required length of time to do

same. The process is very expensive due to the process requirements and materials. Moreover, it has been found

that the life span of such trim components may be limited

because they lose color quickly upon exposure to heat,

sun, chemicals, and the like. The requirements for all

of the rollers, drums, laminates, vacuum- forming dies and

processes, and injection molding equipment is very

expensive. The cost of tooling is very high due to the

requirement of vacuum- form tooling, injection tooling,

trim tooling, drums and rollers, and the like. Moreover,

the trimming of materials after placement into the

vacuum-forming and injection cavities results in much

waste, and lower yields. Problems have also been

experienced with regard to maintaining DOI (depth of

image) , in that DOI may be lost due to deep draws in the

components. Depth of pockets or corners in the final

molded components is also limited due to the dry paint

film, as it may not be over-stretched or it will lose

color and/or gloss.

U.S. Patent No. 5,037,680, incorporated herein by

reference, discloses an exterior automotive component

with a pigmented substrate and a clear coating thereon.

The substrate may be of a thermoplastic polyolefin.

Unfortunately, the clear coating material in the '680 patent is deposited onto the substrate in liquid form,

e.g. spraying, brushing, dipping, flow coating, etc.

This spray or wet application is undesirable for the

reasons set forth above (e.g. environmental concerns,

need for solvents, expensive equipment required, etc.).

It is apparent from the above, that there exists a

need in the art for colored and molded automotive trim

components which: (i) may be manufactured without the

requirement of prior art dry color paint film transfer;

(ii) are colored so as to match or compliment a color of

the surrounding vehicle; (iii) may be manufactured at a

lesser cost than conventional dry paint film techniques;

(iv) have an adequate life span upon exposure to heat,

sun, chemicals, and the like; (v) may be manufactured

without the requirement of needing to pass through chrome

rollers and/or dryers on multiple occasions; (vi) may be

manufactured without excessive capital expenditure; (vii)

may be manufactured without wasting large amounts of

trimmed off materials; (viii) maintain DOI; (ix) are

scratch resistant, have luster, and are resistant to

marring; (x) have high gloss and retention of same; (xi)

have color uniformity; (xii) are resistant to gasoline

and solvents, and acid spotting; (xiii) have satisfactory hardness and abrasion resistance; (xiv) have satisfactory

impact strength; (xv) have acceptable UV resistance;

(xvi) are resistant to water and humidity exposure;

and\or may be manufactured without the need to "spray" on

or otherwise apply a clear coat in liquid form. There

exists a need m the art for molded trim products having

any or all of the aforesaid characteristics, as well as

methods of manufacturing the same .

It is a purpose of this invention to fulfill any and

all of the above-described needs in the art, as well as

other needs which will become apparent to the skilled

artisan from the following detailed description of this

invention.

SUMMARY OF THE INVENTION

An object of th s invention is tne provision of an

exterior automotive trim component which is simple to

construct, economical to manufacture, and effective m

operation.

It is an object of this invention to provide an

exterior automotive trim component which is provided for

exterior appearance purposes defining color which matches

or compliments a surrounding color of a vehicle. It is another object of this invention to provide a

color pigmented molded substrate upon which a

substantially transparent clear coat is provided or

bonded in a non-wet or non-liquid manner. The colored

substrate, in combination with the overlying clear coat,

provides a composite molded trim component having the

durability, gloss and other appearance properties

necessary for satisfactory exterior automotive use.

It is another object of this invention to eliminate

the need for prior art dry color paint film transfer

technology, and to eliminate the need for spray painting

of molded automotive trim components.

It is still another object of this invention to

place a thin clear coat layer laminated to a color

pigmented plastic substrate into an injection mold, and

inject additional plastic into the mold in semi-molten

form behind the clear coat/color laminate in order to

manufacture a molded automotive trim component including

at least three layers.

Yet another object of this invention is to vacuum-

form or thermoform the composite of the clear coat and

color pigmented substrate together into a skin, and then

to insert the vacuum- formed laminate into an injection mold cavity and inject additional plastic material behind

it m order to make a molded automotive trim component .

Another object of this invention is to make an

automotive trim component by only vacuum- forming a

composite laminate of a thin clear coat and a thicker

underlying pigmented substrate.

Anotner object of this invention is to place a clear

coat layer laminated to a carrier (e.g. polyester or the

like) into the cavity of an injection molding apparatus,

and then to injection semi -molten color pigmented

material into the cavity behind the laminate so that the

color pigmented material contacts and bonds with the

clear coat and the final trim product conforms with the

shape of the cavity mold. The carrier can be peeled off

of the clear coat after the product has been cooled and

removed from the injection molding apparatus.

Yet another oo ect of this invention is to extrude a

color pigmented plastic substrate, vacuum- form the same

into a skin, thereafter place it into an injection mold

and inject additional colored or non-colcred plastic

behind it, cool it, with the result being a molded and

colored automotive trim component. In other embodiments of this invention, it is an

object of this invention to simulate glass by providing

all layers of the method and/or resulting product

substantially transparent (at least about 70%

transparent) to visible light. In such embodiments, the

products may be used in place of glass windows on

automobiles and other types of vehicles. Alternatively,

in still other embodiments of this invention, methods of

certain embodiments herein may be used to produce

products that simulate tinted glass with all layers of

such products preferably being at least about 20%

transparent to visible light.

This invention further fulfills the above described

needs in the art by providing a method of making a

colored automotive trim product, the method comprising

the steps of:

providing a substantially transparent clear coat

layer on a carrier layer to form a clear coat laminate;

calendaring the clear coat laminate to a colored

substrate including color pigment material therein using

at least first and second rollers to form a colored

laminate including the clear coat, the carrier layer, and the colored substrate, the colored substrate being opaque

to visible light;

tnermoforπung the colored laminate into a desired

three dimensional shape m a vacuum- forming apparatus to

provide a thermoformed colored laminate;

providing the thermoformed color laminate m a

cavity of an in ection molding apparatus ,-

injecting flowable resin into the cavity of tne

injection molding apparatus behind the thermoformed color

laminate to provide a colored trim product having at

least three layers; and

removing the carrier from the trim product.

This invention further fulfills the above described

needs in the art by providing a method of making a

colored automotive trim product, the method comprising

tne steps of :

providing a suostantially transparent clear coat

layer (77) on a carrier layer (78) to form a clear coat

laminate;

thermoformmg the clear coat laminate into a desired

three dimensional snape;

placing the clear coat laminate into a cavity of an

injection molding apparatus; and injecting a flowable colored material into the

cavity of the injection molding apparatus behind the

clear coat laminate to form a three dimensionally molded

colored product;

removing the carrier from the clear coat; and

using the three dimensionally molded colored product

as a trim product on a vehicle.

This invention further fulfills the above-described

needs in the art by providing an automotive trim product

comprising:

a color pigmented layer having a tensile

strength of at least about 10,000 psi and a thickness of

at least about 0.050 inches;

a substantially transparent clear coat at least

about 90% transparent to visible light rays, the color

pigmented layer and the clear coat being included in a

three-dimensionally shaped and thermoformed laminate; and

said thermoformed laminate useable as an

automotive trim product, wherein said laminate has a

gloss retention of at least about 95%. This invention will now be described with respect to

certain embodiments thereof, along with reference to the

accompanying illustrations.

IN THE DRAWINGS

Figure 1 is a prior art perspective view of an

automobile .

Figure 2 is a prior art side cross-sectional view of

a paint -coated carrier having a clear coat thereon.

Figure 3 is a prior art schematic side elevation

view illustrating a step during the process of making the

laminate of Figure 2.

Figure 4 is a prior art schematic side view

illustrating a laminating step used in making the

laminate of Figure 5.

Figure 5 is a prior art cross-sectional view

illustrating a dry composite paint coat transferred to a

backing sheet during the laminating step (it is noted

that film thicknesses are exaggerated in the drawings

herein and are not to scale, for purposes of simplicity) .

Figure 6 is a prior art schematic view illustrating

a thermo-forming step in which a paint -coated laminate of

Figure 5 is heated prior to vacuum- forming . Figure 7 is a prior art schematic view illustrating

vacuum- forming of the Figure 5-6 laminate.

Figure 8 is a prior art cross-sectional view

illustrating a preliminary step m which a vacuum- formed

laminate is inserted into the cavity of an injection

molding device.

Figure 9 is a prior art cross-sectional view

illustrating the injection of plasticized or semi-molten

material into the Figure 8 injection molding device

behind the vacuum-formed laminate m order to form a

molded automotive trim component or product.

Figure 10 is a prior art cross-sectional view of a

section of the automotive trim component formed m Figure

9.

Figure 11 is a cross-sectional view of a molded

automotive trim laminate according to an embodiment of

this invention.

Figure 12 is a cross-sectional view of a vacuum-

formed automotive trim component being inserted into an

injection molding device according to an embodiment of

this invention.

Figure 13 is a cross-sectional view illustrating

plasticized material being injected into the Figure 12 molding cavity behind the vacuum-formed laminate in order

to manufacture a molded and colored automotive trim

component according to an embodiment of this invention.

Figure 14 is a cross-sectional view illustrating a

substantially planar colored laminate being inserted into

an injection molding device according to an embodiment of

this invention.

Figure 15 is a cross-sectional view illustrating

plasticized material being injected into the molding

device of Figure 14 in order to form a molded automotive

trim component according to an embodiment of this

invention.

Figure 16 is a partial cross-sectional view of an

automotive trim component according to an embodiment of

this invention.

Figure 17 is a cross-sectional view of an automotive

trim component according to another embodiment of this

invention.

Figure 18 is a partial cross-sectional view of an

automotive trim component according to yet another

embodiment of this invention.

Figure 19 is a perspective view illustrating an

injection molding device which may be utilized to manufacture automotive trim components according to any

of the different embodiments of this invention.

Figure 20 is a perspective view illustrating a

composite made up of a thin clear coat on a color

pigmented substrate being positioned within the cavity of

either an injection molding device or a vacuum-forming

device according to certain embodiments of this

invention.

Figure 21 is a perspective view of an injecting

molding device which may be utilized m the manufacture

of automotive trim components according to any of the

different embodiments of this invention.

Figure 22 is a cross-sectional view illustrating the

positioning of a color pigmented substrate and overlying

clear coat lammant in a vacuum- forming device according

to an embodiment of this invention.

Figure 23 is a side cross-sectional view

illustrating vacuum- forming of the laminate of Figure 22.

Figure 24 is a side cross-sectional view of the

three dimensionally molded laminate resulting from the

process of Figures 22-23.

Figure 25 is a side cross-sectional view

illustrating the molded laminate of Figure 24 being 21 placed into an injection molding device, and plasticized

or semi -molten material thereafter being injected into

the molding cavity behind the pre-formed laminate in

order to make a molded automotive trim component

according to an embodiment of this invention.

Figure 26 is a schematic diagram illustrating a

roller apparatus for bonding together a clear coat layer

and a color pigmented thermoplastic layer according to

one embodiment of this invention.

Figure 27 is a cross sectional view of a portion of

a laminate including a clear coat layer mounted on a

carrier layer in certain embodiments of this invention.

The carrier is removed after the laminate has been

thermoformed in an injection molding device or a vacuum-

forming apparatus . The carrier may be removed manually

by peeling.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS OF THIS INVENTION

Referring now more particularly to the accompanying

drawings in which like reference numerals indicate like

parts throughout the several views .

It should be understood that trim products in

accordance with certain embodiments of this invention are adapted to be mounted on vehicles such as that

illustrated in prior art Figure 1, as well as all other

types of automotive vehicles including sedans, station

wagons, limousines, trucks, and the like. The instant

invention relates to the construction of trim components

adapted for use on the exterior of automotive vehicles.

The components are to be provided for exterior appearance

purposes so as to either match the color of the

corresponding vehicle, or to compliment the color of the

corresponding vehicle. Exemplary automotive trim

products which may be made in accordance with the methods

disclosed herein include wheel covers, door sides, bumper

fascia, trunk lids, claddings, body side moldings, roof

moldings, beltline moldings, window moldings, grills, and

the like. In other embodiments, entire exterior

automobile body panels such as hoods, door panels,

quarter panels, trunks, and the like may be made in

accordance with methods and resulting products of this

invention. In certain other embodiments, methods and

products herein may be utilized a components on devices

other than automobiles, such as on snowmobiles, lawn

tractors, and the like. For example, methods and products herein may be used as hoods or other types of

panels on vehicles such as tractors and snowmobiles.

Figure 16 is a side cross-sectional view of an

automotive trim component 71 according to one embodiment

of this invention. Trim component 71 includes base

substrate 73 preferably formed by injection molding or

the like, color pigmented thermoplastic substrate 75

preferably formed by extrusion, and substantially

transparent overlying clear coat layer 77 preferably

formed by extrusion.

According to certain embodiments of this invention,

color pigmented layer 75 and solid (i.e. non-liquid)

clear coat layer 77 may be calendared together to form

laminate 79 of Figure 11. Laminate 79 may then be

vacuum- formed into approximately the shape of the desired

final trim product. Vacuum-formed or thermoformed

laminate 79 may then be placed into a cavity of an

injection molding device, and plasticized or semi -molten

resin material thereafter being injected into the cavity

so as to form base substrate 73 which becomes bonded or

fused to layer 75 due to the heat and pressure m the

cavity. The cavity defines the three dimensional shape

of the final trim product. Figure 16 illustrates a cross-section of the final trim product of this

embodiment .

In accordance with certain embodiments of this

invention, the need for spraying on a paint layer and/or

spraying on or otherwise applying a liquid clear coat

layer is eliminated. Thus, the resulting product can be

made more efficiently, with less capital expenditure as

there is no need for a paint or spray line, and in a more

environmentally safe manner as there is no need for

solvents or other hazardous materials typically utilized

in liquid application processes.

Referring to Figs. 16 and 11, base substrate 73 may

be made from any polymer-based semi-molten resin which is

injected into the cavity of an injection molding device.

Substrate 73 may be transparent or optionally may be

colored or opaque. Molded polymer substrate 73 may be

selected to provide rigidity and other desirable

properties. Suitable polymers for making base substrate

73 include, for example, polyvinyl chloride,

polycarbonate, polystyrene, polypropylene, polyethylene,

acrylonitrile-butadiene-styrene, nylon, co-polymers,

ionomers, polyolefin (TPO), homopolymers co-polymers, and

urethanes. Polyolefin, homopolymers, and co-polymers are thermoplastic resins which have good molding properties

and may be used as substrate 73 in preferred embodiments.

Likewise, polypropylene has many performance properties

suitable for automotive exterior uses, as do acid co-

polymers of polyethylene, all of which may be used as the

material of substrate 73. Substrate 73 may be from about

1.0 to 5.5 mm thick, most preferably from about 2.0 mm to

4.0 mm thick.

Clear coat layer 77 is transparent or substantially

transparent to visible light. In certain preferred

embodiments, clear coat 77 is at least 90% transparent to

visible light rays, more preferably at least 95%

transparent to visible light rays, and most preferably at

least about 98% transparent to visible light rays. Clear

coat layer 77 is provided for giving the trim product a

high gloss finish, protecting color layer 75, and

providing a coating which is resistant to scratching,

abrasions, marring, heat, UV radiation, and weathering.

Clear coat 77 is also flexible and has satisfactory

elongation characteristics during adhesion to color

pigmented layer 75. Different types of materials may be

used to make clear coat 77. Layer 77 may be made, for

example, of a thermoplastic synthetic resinous composition. Clear coat 77 may, for example, include or

be made of a blend of a thermoplastic fluorinated polymer

and an acrylic resin where the polymer component may be a

thermoplastic fluorocarbon such as polyvinylidene

fluoride and the acrylic resin may be polymethyl

methacrylate or polyethyl methacryate resin, or mixtures

thereof. Other materials which may be utilized to form

substantially transparent clear coat 77 include

polycarbonate base available from Avery Dennison (Troy,

Michigan) or Kurz-Hastings (Philadelphia, PA) .

Clear layer 77 may be from about 0.000025 to 0.003

inches thick in certain embodiments of this invention.

Additionally, in certain embodiments, clear coat 77 may

be placed on a polyester or polyethylene carrier, with

the combination being from about 0.5 to 3 mils thick.

The carrier (e.g. polyester or polyethylene carrier)

stays with the clear coat 77 up until the time when the

clear coat is made into a formable skin. The clear coat

is calendared onto the carrier between heated rollers,

e.g. using the apparatus shown in Fig. 26. Fig. 27

illustrates the clear coat 77 en the carrier 78, as a

laminate. For example, the self-supporting carrier may

be removed after the clear coat (and other layers laminated thereto) is thermoformed into the desired

three-dimensional shape, and it may be manually removed

by peeling. This carrier may be from about 1.0 to 2.5

mils thick. The carrier functions to protect the clear

coat during the manufacturing process and also supports

the clear coat layer 77. While the carrier 78 is removed

after thermoforming so that final trim products herein do

no include this carrier, the carrier 78 is typically

supporting the clear coat layer 77 until after it has

been thermoformed (e.g. in a vacuum- forming or injection

molding apparatus) . Thus, when clear coat layer 77 is

referred to herein in the specification (not in the

claims) prior to and during thermoforming it, it is to be

understood that carrier 78 may be attached thereto for

protection and support.

Color pigmented thermoplastic substrate 75 is the

layer in trim product 71 which determines the color of

the trim product. Substrate 75 is capable of being

thermoformed. The color of layer 75 is viewed from the

vehicle's exterior through clear coat 77. Layer 75, in

certain embodiments, may comprise a polyolefinic

thermoplastic resin (TPO) , color producing pigments and

additives, ultraviolet stabilizers, and other additives conventionally used in thermoplastic resins for producing

automotive exterior components. An exemplar material

which may be used as color pigmented layer 75 in certain

embodiments of this invention is Millennium III™, which

is a glass-filled polycarbonate rigid sheet with optional

GE Lexan™ layers on top and bottom (ABA tri -manifold

coextrusion) . Millennium III is available from Spartech

Alloy Plastics, and is a composite product of 20%

(preferably from about 10-30%) glass-filled polycarbonate

that provides the physical properties of glass-filled

polycarbonate with a "Class A" finish of a standard

polycarbonate sheet .

Additional exemplar color materials which may be

used as layer 75 include Montell Hivalloy polyolefins,

where copolymer alloys are created between polyolefins

(e.g. semi-crystalline polymer) and normally incompatible

amorphous polymers. This creates for layer 75 a

continuous polyolefin matrix with dispersed amorphous

phase, where polymers are chemically linked similar to a

graft copolymer. The amorphous polymer components may be

styrene or acrylic. This material for layer 75 has a low

density of from about 0.93 to 0.95 g/cc, excellent

chemical resistance, excellent weatherability (including UV resistance), etc. Both Montell Hivalloy XPA018 30%

glass reinforced resin, and Hivalloy XPA052 high flow

general purpose resin may be used in different

embodiments of this invention. The injection pressure of

these materials, if utilized, is preferably less than

about 15,000 psi in certain embodiments of this

invention, and most preferably less than about 10,000

In certain embodiments of this invention, color-

pigmented layer 75 has a tensile modulus (ASTM D-638,

incorporated herein by reference) of from about 500,000

to 700,000 psi, and more preferably from about 550,000 to

600,000 psi. In certain embodiments, layer 75 has a

specific gravity of from about 0.8 to 1.3, preferably

from about 0.9 to 1.2 In certain embodiments of this

invention, color-pigmented layer 75 has a tensile

strength (ASTM D-638, incorporated herein by reference)

of at least about 10,000 psi, and preferably at least

about 11,000 psi. Layer 75 may have a tensile strength

of from about 11,000 to 12,000 psi. In certain

embodiments of this invention, color-pigmented layer 75

has a flexural modulus (ASTM D-790, incorporated herein

by reference) of from about 700,000 to 800,000 psi, preferably from about 725,000 to 750,000 psi. Also, in

certain embodiments, layer 75 has a flexural modulus of

from about 1900-2000 MPa average. In certain embodiments

of this invention, layer 75 has a flexural strength (ASTM

D-790, incorporated herein by reference) of at least

about 20,000 psi. Layer 75 preferably has a flexural

strength of from about 20,000 to 22,000 psi. In certain

embodiments of this invention, layer 75 has a coefficient

of thermal expansion (ASTM D-696, incorporated herein by

reference) of from about 1.0 x 10^"5 to 5.0 x 10^~5

(in . /in. /degrees F) , and more preferably from about 3.0 x

10^"5 to 3.5 x 10^"5. Layer 75 preferably has a coefficient

of thermal expansion of at least about 3.0 x 10^~s

in. /in. /degrees F. In certain embodiments of this

invention, layer 75 has a hardness (ASTM D-785,

incorporated herein by reference) of at least about 110

(Rockwell "R" ) , and more preferably of at least about 115

(Rockwell "R" ) . In certain embodiments of this

invention, layer 75 has a tensile strength at yield of

from about 50-60 MPa average, a deflection temperature

under load (455 kPa) of from about 90-100 C average, and

a deflection temperature under load (1820 Kpa) of from

about 60-65 C average. The melt temperature of layer 75 is preferably from about 400-600 degrees F, preferably

from about 425-500 degrees F.

Layer 75 also has less sag than other materials such

as Dow M910 ABS and Centrex 811 ASA. For example, in

certain embodiments, when a 6.5 inch span of layer 75 is

exposed to 250 degrees F for one hour to measure sagging

of the layer, suspended layer 75 sags downward less than

about 0.5 inches, preferably less than about 0.3 inches.

In certain embodiments of this invention, color-

pigmented layer 75 may have (e.g. Hivalloy Acrylic/PP

XPA011 from Montell, SAE J1960, exterior) a color shift

(Delta E) , black, of less tnan about 0.5, preferably less

than or equal to about 0.3, and most preferably less than

or equal to about 0.2 (e.g. material 1800 kJ/m²) . Layer 75

may have a color change after 2500 kJ/m² of less than

about 0.3. Layer ^π5 , alone, m certain embodiments of

this invention, may have a gloss retention [e.g. black

color, initial 90.1, 60 degree angle, 2500 kJ/m², to 84]

of at least about 90% and preferably of at least about

93%. At another angle (e.g. 20 degrees viewing), layer

75, alone, m certain embodiments of this invention has a

gloss retention [e.g. black color, initial 83.2, 20

degree angle, 2500 kJ/m², to 74.1] of at least about 80%, and preferably of at least about 89% at this 20 degree

angle. Layer 75, alone in certain embodiments, when run

through 6 months SAE J1976, Florida Test (60 degree

gloss) , has a gloss retention of at least about 90%, and

preferably of at least about 95.0% [ΔE=0.12, ΔL=0.05,

Δa=0, Δb=0.09, Δc=0.08]. As for white color in certain

embodiments of this invention, layer 75 has a gloss

retention of at least about 99% [ΔE=1.8, SAE J1960

Montell Hivalloy acrylic/pp copolymer WXPA012] .

With regard to chemical resistance, color-pigmented

layer 75 preferably passes each of the following tests,

for each of which the following chemicals were applied

with a gause swab and exposure was for 48 hours. The

tests were passed because after application and exposure,

visual inspection evidenced that there was no cracks or

crazing observed. The tests passed were as follows: (a)

at 23 degrees C, 0% strain level, the test was passed for

each of windshield washer fluid, automatic transmission

fluid, tar and road oil remover, brake fluid, coolant

concentrate, motor oil, and ASTM Fuel C + 15% MeOH being

separately applied to layer 75; (b) at 60 degrees C, 0.0%

strain level, the test was passed for each of the

chemicals in (a) above except the fuel; (c) at 23 degrees C, 0.5% strain level, the test was passed for each of the

chemicals in (a) above; (d) at 60 degrees C, 0.5 degrees

C, the test was passed for each of the chemicals in (a)

above except the fuel; (e) at 23 degrees C, 1.0% strain

level, the test was passed for each of the chemicals in

(a) above; and (f) at 60 degrees C, 1.0% strain level,

the test was passed for each of the chemicals in (a)

above except the fuel. Montell Hivalloy WXPA011 is an

exemplar material for layer 75. Many conventional

materials, such as Luran S ASA and Xenoy 1731 craze or

crack and do not pass many of the above tests (especially

the tar and road oil remover, brake fluid, coolant

concentrate, and washer fluid when strain is applied) .

The color imparted to layer 75 may be imparted by

ingredients and techniques known in the art. The color

pigmentation of the resin layer 75 is carried out to

produce a desired value on a color chart. Typically, the

coloration is provided to the resin substrate 75

utilizing various combinations of color pigment additives

such as titanium dioxide, blue tone phthalocyanine green,

yellow tone phthalocyanine green, green tone

phthalocyanine blue, lamp black, and/or carbon black.

The amounts of color additives and the particular combinations thereof utilized to achieve desired color in

layer 75 are known in the art.

Ultraviolet radiation deterioration preventing

elements may also be provided in layer 75 or layer 77.

These include carbon black, white pigments, organic

ultraviolet stabilizers, and other pigments which absorb

and/or reflect ultraviolet radiation.

Referring now to Figures 11-26, it will be described

how automotive trim product 71 is manufactured according

to a first embodiment of this invention. To begin with,

an extruded color pigmented thermoplastic layer 75 and a

separate substantially transparent clear coat web or

layer 77 are provided. These two layers 75 and 77 are

then laminated or bonded together by way of, for example,

the apparatus shown in Figure 26. The clear coat web or

layer 77 may be unwound from roll 81 while color layer 75

is simultaneously unwound from roll 83. Af er passing

over guide rollers 85, color layer 75 and clear coat

layer 77 meet at the nip between heated chrome coated

rollers 87 and 89. The surfaces of rollers 87 and 89 may

be oil-heated to a temperature of from about 220° F. -

275° F. The pressure between rollers 87 and 89 may be

from about 15-50 lbs. per sq. inch in certain embodiments of this invention, more preferably from about 15-30 lbs.

per sq. inch, and most preferably from about 15-20 lbs.

per sq. inch. When layers 75 and 77 pass between rollers

87 and 89, this pressure and heat causes the two layers

to mechanically bond (be laminated together) . The

resulting laminate 79 is fed away from rollers 87 and 89

and preferably stored on a roll. A cross-section of

laminate 79 is shown in Figure 11.

Laminate 79 may then be thermo-formed into a shape

approximating that of the desired final automotive trim

product by way of vacuum-forming the laminate in either

the device of Figures 6-7, or the vacuum- forming device

of Figures 22-23. If the Figure 6-7 vacuum- forming

device is used, then laminate 79 is placed into clamping

frame 45. Clamping frame 45 is then moved along a track

into oven 47 for heating laminate 79 to a thermo-forming

temperature. Laminate 79 may be heated in oven 47 to a

temperature of from about 250° - 400° F. As the preheated

laminate 79 (or 49) sags as shown in Figure 6, it is

moved along with the clamping frame 45 back to its

original position above vacuum- forming buck 51. Laminate

79 is then vacuum- formed into the desired three

dimensional approximate shape. A vacuum is drawn on buck 51 through connection 53 to a vacuum pump. Buck 51 is

then moved toward and into clamping frame 45, where the

vacuum is pulled through holes in the working surface of

buck 51 to force the molten plastic of laminate 79 into

the shape of the working surface of the buck.

Optionally, positive air pressure may be applied to the

free face of the laminate on the opposite side of the

buck in order to increase forming pressure. It is noted

that during the vacuum-forming process, it is preferable

that color layer 75 be in contact with the working

surface of buck 51. Buck 51 stays in place long enough

to cool the plastic laminate 79 to a solid state again

before the buck drops away from frame 45. The result is

a thermo-formed and three dimensionally shaped laminate

91 which is shown in Figure 12. The shape of laminate 91

corresponds to the working surface of buck 51.

It is also possible to utilize the vacuum- forming

device of Figures 22-23 to form substantially planar

laminate 79 into three dimensionally shaped laminate 91.

Referring to Figures 22-24, the vacuum- forming apparatus

includes vacuum molding buck or dye 99, a plurality of

vacuum suction holes 101 in dye 99, and vacuum suction

pump 103 which communicates with holes 101 via conduit 105. An on/off valve 107 is provided so that vacuum pump

103 may selectively vacuum air through holes 101.

Substantially planar laminate 79 is softened by heating

it to a preheating temperature as discussed above.

Following preheating, buck or dye 99 may be raised toward

laminate 79 and vacuum 103 applied to draw the color

layer surface 75 of laminate 79 into contact with the

working surface of dye 99 as shown in Figure 23. After

it is cooled, the resulting vacuum-formed laminate 91 is

illustrated in Figure 24, having a three dimensional

shape approximating that of the desired final automotive

trim component. While the shape illustrated in Figure 24

is not identical to the shape of vacuum- formed laminate

91 in Figure 12, it is pointed out that the vacuum-formed

shape depends on the buck or dye of the vacuum- forming

apparatus, and that the illustrated shapes are provided

for purposes of example only. Either male or female

bucks may be used in vacuum- forming devices in different

embodiments of this invention.

The vacuum- formed three dimensionally shaped

laminate 91 is then placed into cavity 111 of an

injection molding apparatus as shown in either of Figures

12 and 25. Figures 12 and 25 both illustrate cavities of different injection molding apparatus devices, with the

cavities differing by at least the three dimensional

shape of the desired end product. The components ^' of the

injection molding devices of Figures 12 and 25 will be

referred to using the same reference numbers for similar

device components.

Referring to Figures 12 and 25, the injection

molding device includes first and second mold halves 113

and 115. The inner surface of mold half or dye 115 is

three dimensionally shaped so as to approximately match

the shape of the exterior surface of clear coat layer 77

of vacuum-formed laminate 91. Laminate 91 is placed into

cavity 111 so that clear coat layer 77 of laminate 91

comes to rest against the working surface of dye 115.

Thereafter, semi-molten plastic resin 119 is injected

into cavity 111 through aperture 117 provided in dye 113

in order to form molded base substrate 73. The pressure

from the injecting of semi-molten resin 119 into cavity

111, combined with the temperature within the cavity and

the surface of dye 115, causes the semi-molten resin 119

to fuse together with (or bond with) vacuum- formed color

pigmented thermoplastic layer 75. The result is three

layered laminate 71 as shown in Figure 16, which is three dimensionally molded for the desired exterior automotive

application. This represents the final trim product in

this embodiment.

According to another embodiment of this invention,

trim product 71 may be manufactured without vacuum-

forming. Referring to Figures 14-15, thin and/or

flexible substantially planar laminate 79 may be placed

into cavity 111 of an injection molding device without

having previously been vacuum-formed or otherwise pre-

formed. After the substantially planar laminate 79 is

located within cavity 111, semi-molten plastic resin is

injected into cavity 111 through aperture 117. The

pressure caused by the injection of resin 119 into cavity

111, together with the temperature of the resin and the

surface of dye 115, causes laminate 79 to be pressed

tightly against the working surface of mold dye 115

resulting in layer 75 and 77 of laminate 79 being molded

in the shape of dye 115 as shown in Figure 15. The resin

119 which forms substrate 73 is also in the form of the

mold. After being cooled, the result is the final

automotive trim product, a cross-section of which is

illustrated in Figure 16. Figure 18 is a cross-sectional view of a final

automotive trim product 121 according to still another

embodiment of this invention. Trim product 121 includes

clear coat layer 77 and color pigmented thermoplastic

substrate layer 75. No base substrate 73 is provided or

required in this embodiment. Trim product 121 may be

manufactured as follows. Planar laminate 79 may be

manufactured as discussed above. Laminate 79 may then be

vacuum-formed as discussed above. Following such vacuum-

forming, trimming and cooling, we have the final three

dimensionally molded trim product 121 shown in Figure 18.

Injection molding is not utilized. It is noted that in

accordance with the Figure 18 embodiment of this

invention, pigmented color substrate layer 75 may be

relatively thicker than the same color layer 75 in the

Figure 16 embodiment. For example, color pigmented

substrate 75 of trim product 121 may have a thickness of

at least about 0.060 inches.

Figure 17 illustrates a cross-sectional view of a

portion of a final automotive trim product 123 according

to yet another embodiment of this invention. The trim

product of this embodiment includes base substrate 73 and

color pigmented thermoplastic substrate layer 75, but no clear coat layer. Trim product 123 may be manufactured

in certain embodiments of this invention by vacuum-

forming color layer 75 (without a clear coat layer

thereon) as described above into a skin. The three

dimensionally vacuum- formed skin, consisting of layer 75,

is then placed into an injection mold cavity 111 as

described above, and semi -molten plastic material is then

injected into the mold cavity behind the skin so as to

form substrate 73. Thus, trim product 123 may be

manufactured without the need for the rolling assembly

illustrated in Figure 26.

According to still another embodiment of this

invention, clear coat layer 77 can be laminated to a

bright metallic foil (e.g. Al or chrome) layer (i.e.

layer 75 may be this metallic foil-like layer) . This

composite may thereafter be vacuum- formed as discussed

above, then placed into the cavity 111 of an injection

molding device. Then, semi-molten resin can be injected

into the cavity 111 behind the laminate and allowed to

cure, so that the resulting three-layer product has the

appearance of a chrome plated trim part. In such

embodiments, the foil layer may be from about 0.005 to

0.008 inches thick (e.g. chrome foil or brite Al foil), and the clear coat layer 77 may be from about 0.000025 to

0.003 inches thick. This embodiment is advantageous in

that conventional chrome is easy to scratch and weathers

easily. The foil layer may or may not be provided on a

carrier layer in different embodiments of this invention.

In another embodiment of this invention, a single

layer of clear coat 77 may be vacuum formed by itself

into a skin. Such a layer can be from about 3-7 mils

thick. After vacuum-forming, the molded clear layer is

placed into the cavity 111 of an injection molding device

and semi-molten color-pigmented resin is injected into

the cavity behind it to a thickness of from about 1.5 to

5 mm thick to result in the final two-layer trim product.

Figure 19 generally illustrates an injection molding

device 125 which may be utilized in any of the aforesaid

embodiments of this invention. Referring to Figure 19,

injection molding apparatus 125 includes stationary

platen 127, movable platen 129, mold unit 131 including

dies 115 and 117 located between platens 127 and 129,

injection mechanism 132 attached to platen 127, and mold

clamping device 133 attached to movable platen 129. The

injection mechanism 132 includes a heating cylinder, a

screw, a plasticizing space defined between the heating cylinder and the screw, a nozzle, a hopper, a plunger,

and a sleeve which are illustrated and described m more

detail in either of U.S. Patent Nos. 5,562,931 or

5,486,327, the disclosures of which are both hereby

incorporated herein by reference. Injection device 132

causes the semi-molten resin material to be injected into

the cavity 111 as described above by way of an aperture

117 defined in one of the mold halves. Figure 21

illustrates another injection molding device 135 which is

similar to device 125 of Figure 19. Either vertical or

horizontal injection molding devices may be utilized

according to different embodiments of this invention.

The injection molding device of Figure 25, which

also may be used m any of the embodiments of this

invention, may function as both an injection molding

device including cavity 111 as well as a vacuum- forming

device including vacuum 103, valve 107, conduit 105, and

die 99 (or 115) . Thus, the vacuum- forming and injection

molding may be done m separate devices as described

above, or alternatively may be carried out m a single

device as illustrated in Figure 25.

The final automotive trim products 71 and 121

described above are scratch resistant, have good durability, high gloss, good strength hardness, and

satisfactory ultraviolet stabilization. These properties

are described relative to the surface of the products

viewed on the exterior of a vehicle (i.e. the clear coat

side of the products) . The degree of these physical

characteristics regarding gloss, DOI, color uniformity,

gasoline resistance, cleanability, acid spot resistance,

hardness, abrasion resistance, impact strength, UV

resistance, and water/humidity resistance is described

below.

These trim products, with regard to gloss,

preferably have a specular reflectance for the clear coat

surface of at least about 60-65 gloss units at an angle

of 20° from normal, and at least about 75-80 gloss units

at an angle of 60° from normal. Specular reflectance and

other criteria herein are measured prior to buffing and

waxing, and a preferred test method is described m GM

test specification TM-204-A.

Distmctiveness of image (DOI) is a measurement of

the clarity of an image reflected by the finished

surface. Each of these products has a DOI of at least

about 60 units, where 100 is the maximum DOI reading,

measured by a Hunter Lab, Model No. D47R-6F Dorigon gloss meter. Details of this DOI test procedure are described

in GM test specification GM-204-M which is incorporated

herein by reference.

With regard to gasoline resistance, each of these

products experiences substantially no color change,

degradation, tackiness, marring, or the like after being

immersed for 10 seconds, ten (10) times, in gasoline with

a 20 second dry off period between each immersion.

Immediately after the tenth immersion, the surface of

these products preferably passes the thumbnail hardness

test according to GM test specification TM-55-6, which is

incorporated herein by reference.

With regard to cleanability, each of the aforesaid

products preferably can withstand ten rubs with

cheesecloth saturated with 9981062 Naphtha (or currently

used in other approved cleaning solvents) , with no

substantial evidence of staining, discoloration, or

softening of the exterior surface. This test requires no

evidence of color transfer from the test part to the

cloth. One rub consists of one forward and backward

motion.

With regard to acid spotting resistance, each of the

aforesaid trim products preferably withstands exposure to 0.1 N sulfuric acid for sixteen (16) hours without any

evidence of staining, discoloration, or softening of the

painted surface.

As for hardness, each of the aforesaid trim products

has a hardness of at least four based upon the Knoop

hardness test, which is incorporated herein by reference.

As for abrasion resistance, each of the aforesaid

trim parts preferably can withstand the Gravelometer

standard test identified in SAE J-400 at -10° F. with a

minimum rating of 8, this test method being incorporated

herein by reference.

As for impact strength, each of the aforesaid trim

products preferably can withstand at least 20 lbs. per

inch of direct impact with no failure.

As for UV resistance, also known as accelerated

weathering or QUV, each of the aforesaid products

preferably does not show any significant surface

deterioration or embrittlement , loss of adhesion,

objectionable shrinking, or noticeable color or gloss

change after about 500-1,000 hours exposure to UV light

and condensation apparatus per ASTM G-53 using eight hour

UV cycle at 70° C. and four hour humidity cycle at 50° C, this test procedure being incorporated herein by

reference .

As for water and humidity exposure, each of the

aforesaid trim products preferably can withstand ninety-

six hours of humidity exposure at 100% relative humidity

and 100° F . in a humidity cabinet defined in GM test

specification TM553 (incorporated herein by reference) ,

and a two hour water immersion test at 100° F. according

to GM test specification TM55-12 (incorporated herein by

reference) . The resulting product preferably shows no

evidence of blistering when examined one minute after

removal from the test cabinet. Additionally, each of the

aforesaid final trim products preferably can withstand

fifteen cycles of moisture-cold cycle test defined in GM

test specification TM45-61A (incorporated herein by

reference) , without experiencing any visible signs of

cracking or blistering.

In alternative embodiments, methods herein may be

used to produce products that simulate glass windows

(e.g. windshields, side windows, sunroofs, etc.) and the

like. Any of the aforesaid embodiments may be used for

this purpose, with all layers (e.g. 73, 75, 77) of the

product being substantially transparent to visible light (e.g. at least about 40% percent, and preferably at least

about 70%, transparent to visible light) when it is

desirable to simulate clear windows. When it is desired

to simulate tinted windows, all layers (e.g. 73, 75, 77)

are at least about 10% (preferably at least about 20%,

and most preferably about 25%) transparent to visible

light rays. In certain glass simulating embodiments of

this invention, the clear coat layer 77 may be extruded

along with layer 75. These two layers may then be vacuum

formed together into a three dimensional form or shape

that may be used as a windshield, window, or sunroof on

an automobile, or in place of glass in any other suitable

application. Polycarbonate clear substrates may be used

in certain of these glass simulating embodiments of this

invention, as layer 75 and/or 73.

Once given the above disclosure, many other

features, modifications, and improvements will become

apparent to the skilled artisan. Such other features,

modifications, and improvements are, therefore,

considered to be a part of this invention, the scope of

which is to be determined by the following claims.

Claims

I CLAIM :

1. A method of making a colored automotive trim

product, the method comprising the steps of:

providing a substantially transparent clear

coat layer on a carrier layer to form a clear coat

laminate;

calendaring the clear coat laminate to a

colored substrate including color pigment material

therein using at least first and second rollers to form a

colored laminate including the clear coat, the carrier

layer, and the colored substrate, the colored substrate

being opaque to visible light;

thermoforming the colored laminate into a

desired three dimensional shape in a vacuum- forming

apparatus to provide a thermoformed colored laminate;

providing the thermoformed color laminate in a

cavity of an injection molding apparatus;

injecting flowable resin into the cavity of the

injection molding apparatus behind the thermoformed color

laminate to provide a colored trim product having at

least three layers; and

removing the carrier from the trim product.

2. The method of claim 1, where said first recited

providing step includes providing the substantially

transparent clear coat layer in a thickness in certain

areas thereof of from about 0.000025 to 0.003 inches.

3. The method of claim 2 wherein the clear coat

layer is at least about 90% transparent to visible light

rays .

4. The method of claim 1, wherein the clear coat

laminate is from about 0.5 to 3 mils thick.

5. The method of claim 1, wherein the carrier

includes one of polyester and polyethylene.

6. The method of claim 1, wherein said injecting

step includes injecting the flowable resin into the

cavity which has an interior three dimensionally shaped

so that the resulting colored trim product is molded in

the shape of one of: an automotive body side molding, an

automotive roof molding, an automotive window molding, an

automotive front grill, an automotive bumper fascia, and

an automotive wheel cover.

7. The method of claim 1, wherein the flowable

resin injected in said injecting step is molded to a

thickness of from about 1.0 to 5.5 mm in areas thereof.

8. The method of claim 1, wherein the color of the

colored substrate determines the color of the automotive

trim product, and wherein said colored substrate includes

a glass filled polycarbonate.

9. The method of claim 1, wherein the colored

substrate includes a copolymer alloy including at least

one polyolefin and an amorphous polymer.

10. The method of claim 1, wherein the colored

substrate has a tensile modulus pursuant to ASTM D-638 of

from about 500,000 to 700,000 psi, a specific gravity of

from about 0.8 to 1.3, a tensile strength pursuant to

ASTM D-638 of at least about 10,000 psi, a flexural

strength pursuant to ASTM D-790 of at least about 20,000

psi, and a hardness pursuant to ASTM D-785 of at least

about 110 Rockwell R.

11. The method of claim 1, wherein the trim product

has a gloss retention of at least about 95%.

12. A method of making a colored automotive trim

product, the method comprising the steps of:

providing a substantially transparent clear

coat layer (77) from about 0.000025 to 0.003 inches

thick;

thermoforming the clear coat layer into a

desired three dimensional shape;

placing the clear coat layer into a cavity of

an injection molding apparatus; and

injecting a flowable colored material into the

cavity of the injection molding apparatus behind the

clear coat layer to form a three dimensionally molded

colored product; and

using the three dimensionally molded colored

product as a trim product on a vehicle.

13. The method of claim 12, wherein the steps

recited are performed in the order in which they are

recited.

14. The method of claim 12, wherein said

thermoforming step is performed in said injection molding

apparatus .

15. The method of claim 12, wherein said

thermoforming step is performed in a thermoforming

apparatus that is separate and independent from said

injection molding device.

16. A method of making an automotive product, the

method comprising the steps of:

providing a substantially transparent clear

coat layer (77) from about 0.000025 to 0.003 inches

thick;

thermoforming at least the clear coat layer

into a desired three dimensional shape; and

injecting a flowable material into a cavity

behind the clear coat layer to form a three dimensionally

molded automotive product .

17. The method of claim 16, wherein said

thermoforming step includes vacuum forming the clear coat layer, and wherein the flowble material is color

pigmented.

18. An automotive trim product comprising:

a color pigmented layer having a tensile

strength of at least about 10,000 psi and a thickness of

at least about 0.050 inches;

a substantially transparent clear coat at least

about 90% transparent to visible light rays, the color

pigmented layer and the clear coat being included in a

three-dimensionally shaped and thermoformed laminate; and

said thermoformed laminate useable as an

automotive trim product, wherein said laminate has a

gloss retention of at least about 95%.

19. The trim product of claim 18, wherein said

color pigmented layer and said clear coat are in direct

contact with one another, and the trim product further

including a base layer having a thickness of from about

1.0 to 5.5 mm, wherein said clear coat has a thickness of

from about 0.000025 to 0.003 inches, and wherein said

color pigmented layer is located between said base layer

and said clear coat.