Injection molded plastic article with integral weatherable pigmented film surface

Abstract

Molded articles having contoured, decorative outer surfaces are disclosed. The articles comprise a molded polymer substrate and a decorative surfacing film adhered to one side of the substrate. The decorative surfacing film comprises a substantially molecularly unoriented cast polymer film formed from a weatherable polymer. The articles are particularly suited for use as automobile body panels and the like. Also disclosed is a method for making such articles, and a method for making sets of such articles for assembly into automobile bodies and the like.

That which is claimed is: 
     
       1. A decorative surfacing film for in-mold surfacing of a molded plastic article to impart a high quality surface appearance comparable to that of a high quality automotive paint finish, comprising a preformed molecularly unoriented liquid-cast weatherable fluoropolymer film, a bonding layer comprising a preformed film of a melt produced thermoplastic thermoformable olefin polymer different from said cast polymer film, and an adhesive layer adhering said bonding layer to said liquid-cast weatherable fluoropolymer film, said bonding layer having a thickness of at least 2 mils and sufficient to render the preformed decorative surfacing film shape sustaining when thermoformed, said cast polymer film having pigments therein for providing an appearance and color to the molded plastic article comparable to a high quality automotive paint finish. 
     
     
       2. A decorative surfacing film as claimed in claim 1, wherein said liquid cast weatherable fluoropolymer film comprises an alloy of a polyvinylidene fluoride polymer and an acrylic polymer. 
     
     
       3. A decorative surfacing film as claimed in claim 1, wherein said bonding layer is formed of an acrylonitrilebutadiene-styrene polymer. 
     
     
       4. A decorative surfacing film as claimed in claim 1, wherein said bonding layer is formed of a polyolefin. 
     
     
       5. A decorative surfacing film as claimed in claim 4, wherein said bonding layer comprises a chlorinated polyolefin. 
     
     
       6. A decorative surfacing film as claimed in claim 1, wherein said molecularly unoriented cast polymer film has reflective pigments uniformly distributed therein. 
     
     
       7. A decorative surfacing film as claimed in claim 1, wherein said decorative surfacing film has regions thereof which have been subjected to an elongation of about 25% or more. 
     
     
       8. A decorative surfacing film for in-mold surfacing of a molded plastic article to impart a high quality surface appearance comparable to that of a high quality automotive paint finish, comprising a preformed substantially molecularly unoriented cast weatherable polymer film comprising an alloy of polyvinylidene fluoride and an acrylic polymer, a thermoformable bonding layer formed of a melt produced thermoplastic thermoformable polymer different from said cast polymer film, and an adhesive layer between said thermoformable bonding layer and said cast polymer film, said bonding layer having a thickness of at least 0.25 mils and sufficient to render the preformed decorative surfacing film shape sustaining when thermoformed, said cast polymer film having pigments therein for providing the molded plastic article the appearance of a high-quality automobile body paint finish.