Decorative sheet material simulating the appearance of a base coat/clear coat paint finish

Abstract

A flexible decorative sheet material for use in surfacing automobile body panels and the like is disclosed. The sheet material is characterized by having the appearance of a base coat/clear coat paint finish. The material comprises a substantially transparent outer layer, and a pigmented coating on the undersurface of the outer layer which is visible therethrough. The pigmented coating preferably has reflective flakes uniformly distributed therein to impart to the sheet material the appearance of a base coat/clear coat paint finish. Also disclosed are shaped articles which have such sheet materials adhered to one side thereof, and a method for making such sheet materials.

That which is claimed is: 
     
       1. A flexible decorative sheet material for use in surfacing automobile body panels . .and the like.!., said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially transparent .Iadd.preformed film .Iaddend.outer layer formed of a substantially molecularly unoriented cast polymer .Iadd.formed from a member selected from the group consisting of fluoropolymers, acrylate polymers, vinyl polymers and blends thereof, .Iaddend.and a pigmented coating on the undersurface of said .Iadd.preformed film .Iaddend.outer layer and visible therethrough, said pigmented coating having reflective flakes uniformly distributed therein and oriented generally parallel to said outer layer to impart to the sheet material the appearance of a base coat/clear coat paint finish. 
     
     
       2. A decorative sheet material as claimed in claim 1, further comprising an adhesive layer carried by said pigmented coating. 
     
     
       3. A decorative sheet material as claimed in claim 1, wherein said pigmented coating comprises a first pigmented coating on certain portions of the undersurface of the outer layer and visible therethrough, and a second pigmented coating of a different color on certain other portions of the undersurface of the outer layer, which second pigmented coating is also visible therethrough. 
     
     
       4. A decorative sheet material as claimed in claim 1, wherein said outer layer is formed from a substantially clear film. 
     
     
       5. A decorative sheet material as claimed in claim 4, wherein said pigmented coating is of a thickness less than said substantially clear film. . . 
     
     
       6.  A decorative sheet material as claimed in claim 4, wherein said substantially clear film is formed from a weatherable polymer selected from the group consisting of fluoropolymers, acrylate polymers, urethane polymers, vinyl polymers, and blends thereof..!. 
     
     
       7. A flexible decorative sheet material for use in surfacing automobile body panels . .and the like.!., said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a clear substantially molecularly unoriented weatherable .Iadd.preformed polymer .Iaddend.film .Iadd.formed from a member selected from the group consisting of fluoropolymers, acrylate polymers, vinyl polymers and blends thereof, .Iaddend.and a pigmented coating on the undersurface of said .Iadd.preformed .Iaddend.film and visible therethrough, said pigmented coating having reflective flakes uniformly distributed therein in generally parallel alignment to said film to impart to the sheet material the appearance of a base coat/clear coat paint finish. 
     
     
       8. A decorative sheet material as claimed in claim 7, wherein the mean angle of inclination of said flakes to said film is less than about 6.5 degrees. 
     
     
       9. A decorative sheet material as claimed in claim 7, wherein said pigmented coating is of a thickness less than said film. . . 
     
     
       10.  A decorative sheet material as claimed in claim 7, wherein said weatherable film comprises a polymer selected from the group consisting of fluoropolymers, acrylate polymers, urethane polymers, vinyl polymers, and blends thereof..!. 
     
     
       11. A decorative sheet material as claimed in claim 7, further comprising an adhesive layer carried by said pigmented coating. 
     
     
       12. A flexible decorative sheet material for use in surfacing automobile body panels . .and the like.!., said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a clear, substantially colorless and substantially molecularly unoriented cast .Iadd.preformed .Iaddend.polymer film .Iadd.formed from a member selected from the group consisting of floropolymers, acrylate polymers, vinyl polymers and blends thereof, .Iaddend.and a pigmented coating on the undersurface of said .Iadd.preformed .Iaddend.film and visible therethrough, said pigmented coating having a thickness less than said film and including reflective metallic flakes uniformly distributed therein and oriented in generally parallel alignment to said film to impart to the sheet material the appearance of a base coat/clear coat paint finish. . .13. A decorative sheet material as claimed in claim 12, wherein said film comprises a polymer selected from the group consisting of fluoropolymers, acrylate 
     
     
        polymers, urethane polymers, vinyl polymers, and blends thereof..!.14. A decorative sheet material as claimed in claim . .13.!. .Iadd.12.Iaddend., 
     
     
        wherein said pigmented coating is of a thickness less than said film. 15. A decorative sheet material as claimed in claim 14, wherein the mean angle of inclination of said flakes to said film is less than about 6.5 
     
     
        degrees. 16. A shaped article having a contoured decorative outer surface, comprising a supporting substrate and a decorative sheet material adhered to one side of said substrate and conforming to said contoured surface, said decorative sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially clear .Iadd.preformed film .Iaddend.outer layer formed of a substantially molecularly unoriented cast polymer .Iadd.formed from a member selected from the group consisting of fluoropolymers, acrylate polymers, vinyl polymers and blends thereof, .Iaddend.and a pigmented coating on the undersurface of said .Iadd.preformed film .Iaddend.outer layer and visible therethrough, said pigment coating having reflective flakes uniformly distributed therein to impart to the outer surface of the article the appearance of a base 
     
     
        coat/clear coat paint finish. 17. A shaped article as claimed in claim 16, wherein said substantially clear outer layer comprises a substantially 
     
     
        molecularly unoriented cast film. 18. A shaped article as claimed in claim 16, wherein said pigmented coating has reflective metallic flakes 
     
     
        uniformly distributed therein. 19. A shaped article as claimed in claim 
     
     
        18, wherein said supporting substrate is a rigid metal substrate. 20. A shaped article as claimed in claim 18, wherein said supporting substrate 
     
     
        is a molded polymer substrate. 21. A shaped article as claimed in claim 18, further comprising an adhesive layer carried by said pigmented coating and adhered to said supporting substrate. .Iadd.22. A flexible decorative sheet material for use in surfacing automobile body panels, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially transparent preformed film outer layer formed of a substantially molecularly unoriented cast polymer comprising an alloy of polyvinylidene fluoride and an acrylic polymer and a pigmented coating on the undersurface of said preformed film outer layer and visible therethrough, said pigmented coating having reflective flakes uniformly distributed therein and oriented generally parallel to said outer layer to impart to the sheet material the appearance of a base coat/clear coat paint finish..Iaddend..Iadd.23. A flexible decorative sheet material for use in surfacing automobile body panels, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a clear, substantially molecularly unoriented weatherable thermoformable film comprising an alloy of polyvinylidene fluoride and an acrylic polymer and a thermoformable pigmented coating on the undersurface of said film and visible therethrough, said pigmented coating comprising an alloy of polyvinylidene fluoride and an acrylic polymer and having reflective flakes uniformly distributed therein in generally parallel alignment to said film to impart to the sheet material the appearance of a base 
     
     
        coat/clear coat paint finish..Iaddend..Iadd.24.  A shaped article having a contoured decorative outer surface, comprising a molded polymer supporting substrate and a flexible decorative sheet material adhered to one side of said substrate and conforming to said contoured surface, said decorative sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially clear outer layer formed of a substantially molecularly unoriented thermoformable polymer comprising an alloy of polyvinylidene fluoride and an acrylic polymer and a pigmented coating on the undersurface of said outer layer and visible therethrough, said pigment coating comprising an alloy of polyvinylidene fluoride and an acrylic polymer and having reflective flakes uniformly distributed therein to impart to the outer surface of the article the appearance of a base coat/clear coat paint finish..Iaddend..Iadd.25. A shaped article having a contoured decorative outer surface, comprising a molded polymer supporting substrate and a flexible decorative sheet material adhered to one side of said substrate and conforming to said contoured surface, said decorative sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially clear outer layer formed of a substantially molecularly unoriented thermoformable polymer formed from a member selected from the group consisting of fluoropolymers, acrylate polymers, vinyl polymers and blends thereof, a pigmented coating on the undersurface of said outer layer and visible therethrough, said pigmented coating comprising a thermoformable polymer having reflective flakes uniformly distributed therein to impart to the outer surface of the article the appearance of a base coat/clear coat paint finish, and a polyolefin polymer film layer having one surface thereof laminated to said pigmented coating by an intermediate adhesive bonding layer and having the opposite surface thereof adhered to said molded polymer supporting 
     
     
        substrate..Iaddend..Iadd.26.  A flexible decorative sheet material for use in surfacing automobile body parts, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially transparent preformed film outer layer formed of a substantially molecularly unoriented cast polymer formed from a member selected from the group consisting of floropolymers, acrylate polymers, vinyl polymers and blends thereof, and a pigmented coating on the under surface of said preformed film outer layer and visible therethrough, said pigmented coating having reflective flakes uniformly distributed therein and oriented generally parallel to said outer layer to impart to the sheet material the appearance of a base coat/clear coat paint finish..Iaddend..Iadd.27. A flexible decorative sheet material for use in surfacing automobile body parts, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a clear, substantially molecularly unoriented weatherable preformed polymer film formed from a member selected from the group consisting of floropolymers, acrylate polymers, vinyl polymers and blends thereof, and a pigmented coating on the under surface of said preformed film and visible therethrough, said pigmented coating having reflective flakes uniformly distributed therein in generally parallel alignment to said film to impart to the sheet material the appearance of a base coat/clear coat paint finish..Iaddend..Iadd.28. A flexible decorative sheet material for use in surfacing automobile body parts, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a clear, substantially colorless and substantially molecularly unoriented cast preformed polymer film formed from a member selected from the group consisting of floropolymers, acrylate polymers, vinyl polymers, and blends thereof, and a pigmented coating on the under surface of said preformed film and visible therethrough, said pigmented coating having a thickness less than said film and including reflective metallic flakes uniformly distributed therein and oriented in generally parallel alignment to said film to impart to the sheet material the appearance of a base coat/clear coat paint finish..Iaddend..Iadd.29. A flexible decorative sheet material for use in surfacing automobile body parts, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a substantially transparent preformed film outer layer formed of a substantially molecularly unoriented cast polymer comprising an alloy of polyvinylidene fluoride and an acrylic polymer and a pigmented coating on the under surface of said preformed film outer layer and visible therethrough, said pigmented coating having reflective flakes uniformly distributed therein and oriented generally parallel to said outer layer to impart to the sheet material the appearance of a base coat/clear coat 
     
     
        paint finish..Iaddend..Iadd.30.  A flexible decorative sheet material for use in surfacing automobile body parts, said sheet material being characterized by having the appearance of a base coat/clear coat paint finish when viewing the outer surface thereof, and comprising a clear, substantially molecularly unoriented weatherable thermoformable film comprising an alloy of polyvinylidene fluoride and an acrylic polymer and a thermoformable pigmented coating on the under surface of said film and visible therethrough, said pigmented coating comprising an alloy of polyvinylidene fluoride and an acrylic polymer and having reflective flakes uniformly distributed therein in generally parallel alignment to said film to impart to the sheet material the appearance of a base coat/clear coat paint finish..Iaddend.