United States Patent
`
`[19]
`
`Dunning et al.
`
`[11]
`
`[45]
`
`4,101,698
`
`Jul. 18, 1978
`
`[54]
`
`[75]
`
`ELASTOMERIC REFLECTIVE METAL
`SURFACES
`
`Inventors:
`
`Richard E. Dunning, Munster, Ind.;
`Victor H. Rampelherg, Flossmoor,
`Ill.
`
`[73] Assignee:
`
`Avery International Corp., San
`Marino, Calif.
`
`3,720,567
`3,744,835
`3,770,545
`3,843,475
`3,915,809
`
`..... 428/31 X
`Shanok et a1.
`.......
`3/1973
`
`Carbone et al.
`.
`. 293/71 R X
`7/1973
`...... 52/716 X
`Jackson ............
`11/1973
`
`..... 52/716 X
`10/1974 Kent .... ....
`10/1975 Wheatley ......................... 427/404 X
`
`Primary Examz'ner——-George F. Lesmes
`Assistant Examiner——Alexander S. Thomas
`Attorney, Agent, or Firm—Christie, Parker & Hale
`
`Appl. No.2 595,547
`
`[57]
`
`ABSTRACI‘
`
`An elastomeric transfer laminate for providing decora-
`tive reflective metal finishes on the outer surfaces of
`articles of various shapes includes an effectively trans-
`parent elastomeric layer, such as polyurethane film, and
`a layer of highly reflective metal, such as chromium,
`bonded to the elastomeric layer. The metal is applied in
`microscopically discontinuous quantities, but
`in an
`amount to form an apparently visually continuous, pla-
`nar, highly reflective surface. A typical technique is
`vapor deposition. The elastomeric layer provides an
`effectively transparent protective outer covering for
`the reflective metal layer when the laminate is bonded
`to a substrate. The laminate can be stretched to conform
`to three-dimensional shapes, and bonded to an elasto-
`meric substrate, such as urethane rubber, to produce an
`article having a reflective metal surface which can be
`distorted temporarily during use without disrupting the
`reflectivity of the metal layer.
`
`12 Claims, 10 Drawing Figures
`
`[21]
`
`[22]
`
`[51]
`[52]
`
`[53]
`
`[56]
`
`Jul. 14, 1975
`Filed:
`Int. Cl.2 ............................................ .. B60R 13/00
`U.S. Cl. ...................................... 428/31; 427/404;
`427/290; 428/204; 428/209; 428/344; 428/425;
`428/40; 428/914; 156/230
`Field of Search ................... 428/31, 33, 349, 423,
`428/195, 379, 40, 344, 462, 425, 204;
`427/ 123-124, 404, 89; 52/716-717; 296/1 R, 28
`R, 29, 31 P; 293/71, 98, DIG. 4, 62; 350/109
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`5/1936 Wickmann ....................... 428/148 X
`6/1954
`Judd ..........
`427/299 X
`2/1963 Harwig .............
`427/404 X
`10/1964
`Palmquist et al.
`428/462 X
`12/1965 Newman ...............
`427/124 X
`2/1970
`Fitzgerald et al.
`296/31 P
`7/1971
`Shanok .............
`296/28 R
`8/1972 Ruff ................................... 52/716 X
`
`
`
`2,039,372
`2,680,695
`3,076,727
`3,152,950
`3,223,554
`3,493,257
`3,590,768
`3,687,792
`
`//0
`
`Zfl - A754/£5///Z
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`
`Exhibit 1008
`Wavelock
`Page 1
`(cid:58)(cid:68)(cid:89)(cid:72)(cid:79)(cid:82)(cid:70)(cid:78)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:40)(cid:91)(cid:75)(cid:76)(cid:69)(cid:76)(cid:87)(cid:3)(cid:20)(cid:19)(cid:19)(cid:27)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:51)(cid:68)(cid:74)(cid:72)(cid:3)(cid:20)
`
`

`
`U.S. Patent
`
`Julyl8,1978
`
`Sheetl of2
`
`4,101,698
`
`
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`Exhibit1003
`Page2
`(cid:58)(cid:68)(cid:89)(cid:72)(cid:79)(cid:82)(cid:70)(cid:78)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:40)(cid:91)(cid:75)(cid:76)(cid:69)(cid:76)(cid:87)(cid:3)(cid:20)(cid:19)(cid:19)(cid:27)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:51)(cid:68)(cid:74)(cid:72)(cid:3)(cid:21)
`
`

`
`U.S. Patent
`
`July18, 1978
`
`Sheet2 of2
`
`4,101,698
`
`vEi‘<~5'
`
`£9
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`Wavelock
`Exhibit1003
`Page3
`(cid:58)(cid:68)(cid:89)(cid:72)(cid:79)(cid:82)(cid:70)(cid:78)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:40)(cid:91)(cid:75)(cid:76)(cid:69)(cid:76)(cid:87)(cid:3)(cid:20)(cid:19)(cid:19)(cid:27)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:51)(cid:68)(cid:74)(cid:72)(cid:3)(cid:22)
`
`

`
`1
`
`4,101,698
`
`ELASTOMERIC REFLECTIVE METAL SURFACES
`
`BACKGROUND
`
`This invention relates to decorative laminates, and
`more particularly to a transfer laminate for forming
`elastomeric reflective metal surfaces on articles of man-
`ufacture.
`
`In the past, highly reflective metal surfaces have been
`used on many decorative articles. A typical use is in
`metal bumpers and trim parts for automobiles. Chrome
`plating is chiefly used because of its high reflectivity,
`corrosion resistance, and abrasion resistance.
`Because of the recent federal laws requiring impact-
`absorbing bumpers on motor vehicles, bumpers on some
`late-model automobiles have been made from elasto-
`meric materials such as urethane rubber. These bumpers
`have advantages over their chrome-plated counterparts
`in terms of lighter weight, resistance to corrosion, and
`ability to absorb impact by deforming temporarily with-
`out being permanently damaged. Such bumpers are
`typically made from pigmented rubber without
`the
`common bright reflective metal surfaces. Despite their
`disadvantages, the standard chrome-plated metal bum-
`pers are still used in many automobiles where the bright
`reflective metal finishes are more desirable.
`The reflective metal trim parts on automobiles are
`typically made from metal castings which are chrome-
`plated and commonly attached to the automobile body
`by metal clips or fasteners. The disadvantages of such
`trim parts include the additional weight added to the
`automobile,
`time-consuming and relatively expensive
`attachment techniques, and corrosion problems result-
`ing because the trim parts are made from a metal which
`is different from that of the automobile body and
`thereby causes corrosion from electrolysis of the dissim-
`ilar metals. Despite these problems, chrome-plated
`metal trim parts continue in use today, at least in part
`because of the relative ease with which differently
`shaped surface configurations can be plated with highly
`reflective, abrasion-resistant and corrosion-resistant
`metals such as chrome.
`
`SUMMARY
`
`This invention is based on the recognition that 21 met-
`allized elastomeric laminate can provide a bright reflec-
`tive finish on deformable articles, such as impact-
`absorbing bumpers of automobiles, and also provide
`bright reflective surfaces on molded parts of three-di-
`mensional shapes as an alternative to chrome plating.
`Briefly, the invention provides a transfer laminate
`having a flexible transparent, or translucent, elastomeric
`layer, and a layer of metal bonded to the elastomeric
`layer in separate microscopically discontinuous planar
`quantities of high reflectivity. The metal layer is depos-
`ited so it forms an apparent visually continuous reflec-
`tive surface. The metallized elastomeric layer is at-
`tached to a substrate, either by an adhesive, or by being
`integrally bonded to the substrate surface, to provide a
`reflective metal finish which is capable of being de-
`formed. The laminate can either be used as an impact-
`absorbing surface which distorts and returns to its origi-
`nal position, without destroying the reflectivity of the
`metal surface; or it can be distorted sufficiently to pro-
`vide a reflective metal surface finish for three-dimen-
`sional contoured shapes, without disrupting the contin-
`uous reflectivity of the metallized surface.
`
`5
`
`10
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`15
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`20
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`25
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`30
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`35
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`40
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`65
`
`2
`The transparent, or translucent, elastomeric layer
`provides a protective outer covering for the metal layer
`which is bonded to the undersurface of the elastomeric
`
`layer. The metal is a highly reflective metal, especially
`one having good resistance to corrosion and abrasion.
`Chromium is the preferred metal, although other bright
`reflective metals capable of being vacuum-deposited
`can be used, such as nickel; nickel and chromium alloys
`such as Nichrome; alloys of iron and chromium, or iron,
`nickel and chromium, such as stainless steel; aluminum;
`alloys of aluminum, such as aluminum and chromium;
`tin; antimony; magnesium;
`indium; silver; platinum;
`rhodium; and palladium.
`The elastomeric layer is a relatively thin, self-sup-
`porting film which is flexible and foldable, and is also
`capable of returning substantially to its original position
`when stretched or deformed. More specifically,
`the
`elastomeric layer is not only plastically deformable, i.e.,
`able to be stretched or molded to certain shapes or
`contours under pressure, but it also must be sufficiently
`elastic to return to its original form after the deforma-
`tion load is released. Thus, polyester films such as Du
`Pont’s “Mylar,” or plastic films such as polyethylene, or
`ABS are not suitable. On the other hand, the elasto-
`meric sheet need not be one which is highly elastic,
`although one which is elastic within a wide range of
`deformation is -desirable. Polyurethane film sheeting is
`the desired elastomeric sheet material.
`The metal layer is applied to the elastomeric film in
`separate, discontinuous or captured, generally planar
`reflective segments, preferably being applied in individ-
`ual microscopic dots by vacuum-deposition. The metal
`also can be applied by electroless plating techniques
`which deposit the metal on the film in essentially dis-
`crete selected areas of the film. The metal is deposited in
`an amount and in a manner which provides a visually
`continuous, planar, reflective metallized surface. How-
`ever, since the metal is actually applied in microscopic
`captured reflective metal segments or dots, the metal is
`preserved in its highly reflective planar condition after
`the elastomeric layer, and its adhesive or bonding layer,
`stretch or deform and then return to its original form. In
`effect, the metal is in discrete particles which are free to
`float as islands. A non-elastomeric film does not move
`around enough to allow this phenomenon to occur.
`To reinforce the opacity of the reflective metal layer,
`a separate opaque layer is applied to the undersurface of
`the metal layer. An appropriate adherence layer is then
`formed on the undersurface of the opaque layer for
`attaching the laminate to a substrate. The adherence
`layer can be a layer of adhesive, such as a pressure-sen-
`sitive, or heat-activated adhesive. The adhesive layer
`also may be pigmented and serve as the opaque layer in
`addition to the adherence layer. The laminate can be
`attached to the surface of a substrate by the adhesive, or
`it can be integrally bonded to the substrate by using a
`primer layer in place of the adhesive layer to improve
`the integral bond between the laminate and the sub-
`strate.
`
`This invention provides an improvement over the
`common chrome-plated metal trim parts for automo-
`biles, or other articles having three-dimensional surface
`configurations. For example, contoured trim parts
`which fit around the headlamps or tail lights of automo-
`biles can be made from injection—molded plastic rather
`than metal castings. The metallized elastomeric lami-
`nate of this invention can be stretched to conform to the
`three-dimensional contoured surfaces of these plastic
`
`Wavelock
`Exhibit1003
`Page4
`(cid:58)(cid:68)(cid:89)(cid:72)(cid:79)(cid:82)(cid:70)(cid:78)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:40)(cid:91)(cid:75)(cid:76)(cid:69)(cid:76)(cid:87)(cid:3)(cid:20)(cid:19)(cid:19)(cid:27)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:51)(cid:68)(cid:74)(cid:72)(cid:3)(cid:23)
`
`

`
`3
`trim parts without disrupting the reflectivity of the
`metal layer.
`The laminate also can provide a bright reflective
`metal finish on deformable articles such as articles sub-
`ject to impacts. A typical use is for the impact-absorbing
`bumpers used in many late-model automobiles. For
`example, a laminate comprising a transparent elasto-
`meric film and an undersurface of vacuum-deposited
`metal, such as chromium, can be integrally bonded to
`the molded elastomeric impact-absorbing article. In this
`instance, the laminate is placed in a mold cavity, and an
`elastomeric molding compound, such as urethane rub-
`ber,
`is injected into the mold cavity under pressure
`against the metallized layer to stretch the laminate so it
`conforms to the shape of the molded article and bonds
`to the outer surface of the article.
`As an alternative, the metallized elastomeric transfer
`laminate can be part of a hot transfer sheet in which the
`laminate is releasably attached to a carrier. The heat and
`pressure of the molding operation can be used to sepa-
`rate the elastomeric laminate from the carrier in addi-
`tion to bonding the laminate to a molded article.
`The invention provides an end-product comprising
`an elastomeric molded article having an integrally
`bonded elastomeric reflective metal surface. The trans-
`parent elastomeric sheet provides a protective covering
`for the reflective metal layer, and also allows the metal
`layer to be distorted when the molded article is subject
`to impact, without disrupting the reflectivity of the
`metal layer.
`These and other aspects of the invention will be more
`fully understood by referring to the following detailed
`description and the accompanying drawings.
`DRAWINGS
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`FIG. 1 is a fragmentary schematic cross-sectional
`elevation view showing a method of making one em-
`bodiment of the laminate according to this invention;
`FIG. 2 is a fragmentary schematic cross-sectional
`elevation view showing a method of making an alter-
`nate embodiment of the laminate;
`FIG. 3 is a fragmentary schematic cross-sectional
`elevation view showing a method of making a further
`alternate embodiment of the laminate;
`FIG. 4 is a fragmentary schematic cross-sectional
`elevation view showing the laminate of this invention
`bonded to a contoured outer surface of a substrate;
`FIG. 5 is a fragmentary schematic cross-sectional
`elevation view showing the laminate of this invention in
`preparation for being bonded to the surface of an injec-
`tion-molded article;
`FIG. 6 is a fragmentary schematic cross-sectional
`elevation view showing an injection-molding machine
`‘in a closed position prior to injection-molding of a plas-
`tic molding compound against the laminate of this in-
`vention;
`FIG. 7 is a fragmentary schematic cross-sectional
`elevation view similar to FIG. 6 showing the injection-
`molding machine in an open position after the molded
`article is injection-molded and prior to separating the
`article from the mold;
`FIG. 8 is a fragmentary schematic cross-sectional
`elevation view showing the laminate of this invention in
`the form of a hot transfer sheet in preparation for being
`bonded to the surface of an injection-molded article;
`FIG. 9 is a fragmentary schematic cross-sectional
`elevation view showing an injection-molding machine
`in its closed position prior to injection-molding of a
`
`45
`
`50
`
`55
`
`65
`
`4,101,698
`
`4
`plastic molding compound against the laminate of FIG.
`8; and
`FIG. 10 is a fragmentary schematic cross-sectional
`elevation view similar to FIG. 9 showing the injection-
`molding machine in its retracted open position in which
`the decorative portion of the laminate of FIG. 8 has
`been transferred to the injection-molded article and
`prior to the injection-molded article being removed
`from the mold.
`
`DESCRIPTION
`
`Referring to FIG. 1, an elastomeric laminate 10 ac-
`cording to this invention includes a carrier sheet 12
`having a release coat 14 overlying the carrier sheet. A
`layer 16 of synthetic resinous elastomeric material, such
`as polyurethane, is coated over the release coating 14 to
`form a relatively thin, continuous, planar flexible and
`foldable elastomeric film or skin coat after the coating
`sets. A layer of metal 18, to be described in detail below,
`is applied to the surface of the elastomeric film 16.
`Preferably, the carrier sheet 12 may be any carrier
`sheet or web. For example, it may be a polyester film
`sheet of polyethylene terephthalate, such as “Mylar”
`(trademark of Du Pont), or a polyester film such as
`“Melinex” (trademark of Imperial Chemical Industries),
`or a web of other plastic sheeting such as polyvinyl
`chloride, ABS, cellophane, or cellulose acetate.
`The release layer 14 may be any conventional release
`coating, such as those having a wax, paraffin or silicone
`base, for enabling the carrier 12 to be stripped from the
`elastomeric film 16.
`The elastomeric film 16 preferably is a relatively thin,
`flexible and foldable sheet which is capable of being
`stretched or deformed to a desired shape under pres-
`sure, but will return to substantially its original shape
`after the stretching or deformation force is released.
`The elasticity of the film 16 may be the type which has
`a “memory," i.e., is capable upon removal of a deform-
`ing load, of returning to its “set” configuration with
`time and relaxation. The flexible or stretchable materi-
`als to be avoided are those which stretch readily, with
`slight deformation, beyond their elastic limit. Prefera-
`bly, the elastomeric film 16 is transparent, or at least
`translucent, relatively durable and not relatively abrad-
`able. The elastomeric film 16 also has a sufficient refrac-
`tive index when transparent to allow the metal layer 18
`to appear as though it is a surface layer and a smooth
`skin, so as not to disrupt reflection from the metal layer
`18. The preferred elastomer is a thermoplastic or ther-
`mosetting polyurethane film. Other plastic films such as
`polyvinyl butyral, polyvinyl acetal, transparent vinyls
`such as polyvinyl chloride, flexible polypropylenes or
`polyacrylates, Mylar, or Melinex are not suitable. These
`films are extensible for the most part, but they do not
`have the elastomeric qualities necessary for the present
`invention. Natural or synthetic rubber such as styrene
`butadiene thermoplastic rubber or polypropene rubber
`also are not desirable because they are not sufficiently
`transparent.
`The layer 18 is made from a highly reflective, corro-
`sion and abrasion-resistant metal, such as chromium.
`The metal is preferably applied by vacuum deposition
`techniques which bond the metal to the elastomeric
`film. Preferably, the reflective metal layer is deposited
`in a layer having a thickness of 0.01 mil or less, the metal
`layer being vacuum-deposited in discontinuous quanti-
`ties, or separate planar reflective segments such as dots,
`which are discontinuous but which are deposited so
`
`Exhibit 1003
`Wavelock
`Page 5
`(cid:58)(cid:68)(cid:89)(cid:72)(cid:79)(cid:82)(cid:70)(cid:78)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:40)(cid:91)(cid:75)(cid:76)(cid:69)(cid:76)(cid:87)(cid:3)(cid:20)(cid:19)(cid:19)(cid:27)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:51)(cid:68)(cid:74)(cid:72)(cid:3)(cid:24)
`
`

`
`4,101,698
`
`5
`close together that they give the optical visual effect of
`a continuous, highly reflective metallized surface.
`A layer 20 of adhesive overlays the reflective metal
`layer 18 to provide means for adhering the laminate 10
`to a substrate. The adhesive 20 is one which not only
`bonds to the metal layer 18, but also is a flexible perma-
`nently thermoplastic adhesive which will not disrupt
`the ability of the laminate to elastically deform and
`return to its original shape. In certain instances the layer
`of adhesive need not be provided when adherence to a
`substrate may be provided by other means described
`below.
`To maximize the desired continuous bright reflective
`effect of the metallized layer 18, a variety of means can
`be used to reinforce the opacity of the metallized layer.
`For example, the adhesive layer 20 may include a black
`pigment, white pigment, or aluminum flakes to provide
`the necessary opaque undersurface for the reflective
`metal layer 18.
`FIG. 2 shows an alternate elastomeric laminate
`which includes an opaque layer 22 of a second vacuum-
`deposited metal such as tin, silver, or aluminum, for
`example. A layer 24 of a flexible adhesive is then coated
`on the opaque metal layer 22.
`FIG. 3 shows another alternate embodiment in which
`the opacity of the metal layer 18 is reinforced by an
`opaque layer 26 of pigment, such as a black pigment,
`white pigment, or aluminum flakes in a suitable liquid
`base coated over the layer 18. Preferably, such a pig-
`mented opaque layer 26 is stretchable in much the same
`way as the elastomeric film 16. For example, the desired
`opaque pigment can be dispersed in a layer of a
`theremoplastic polyurethane coated over the metal
`layer 18. The pigment also can be dispersed in a suitable
`ethylene, vinyl, or acrylic rubber base for coating over
`the reflective metal layer.
`The pigmented opaque layer 26 is then coated with a
`layer of adhesive 28. FIGS. 2 and 3 show the alternate
`types of adhesives which can be used. The adhesive 24
`in FIG. 2 illustrates a heat—activated adhesive, and the
`adhesive layer 28 in FIG. 3 illustrates a pressure-sensi-
`tive adhesive having a release liner 30.
`FIG. 4 illustrates one preferred use of the elastomeric
`laminate of this invention. The elastomeric film 16,
`together with the reflective metal
`layer 18, and the
`adhesive layer 20 are released from the carrier 12
`(shown in FIG. 1) in preparation for being attached to
`the exterior surface of a substrate. The elastomeric film
`16 can be stretched to conform to the three-dimensional
`shape of a contoured exterior surface of the substrate.
`The vapor-deposited metal layer 18, being applied in
`microscopic discontinuous dots,
`is capable of being
`distorted with the elastomeric film 16 to conform to the
`three-dimensional shape of the substrate, without dis-
`rupting the continuous, planar, highly reflective appear-
`ance of the metallized finish. The substrate to which the
`laminate is attached is illustrated in FIG. 4 as a rigid
`molded plastic article 31 having a three-dimensional
`contoured outer surface 32. For example, the plastic _
`molded article can be scrollwork attached to the side 33
`of an automobile by a layer 34 of a suitable bonding
`material. The laminate is bonded to the contoured sur-
`face 32 of the plastic trim strip so that the reflective
`metal layer 18 faces through the transparent elastomeric
`film 16 which acts as a protective outer covering for the
`metal layer. The adhesive layer 20 may be any perma-
`nent adhesive capable of bonding the metal layer 18 to
`the rigid plastic article. A vinyl coating such as Union
`
`5
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`25
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`45
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`65
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`6
`Carbide’s VMCH vinyl resin (copolymer of 85 to 88%
`vinyl chloride, 10.8 to 14.2% vinyl acetate, and 0.8 to
`1.2% maleic acid), as well as many acrylic adhesives,
`can be used. Other means for bonding the laminate to a
`rigid plastic article will be described below.
`Thus, the invention provides means for transferring
`highly reflective elastomeric metal surfaces to three-di-
`mensional molded plastic articles, such as trim parts for
`automobiles. When used as trim parts for automobiles,
`the invention has advantages over chrome-plated metal
`trim parts in terms of reduced weight, less cumbersome
`and costly attachment techniques, and reduced corro-
`sion.
`FIG. 5 shows an elastomeric laminate 36 which is
`
`similar to the laminate 10 in that it includes a transparent
`elastomeric film 16 coated onto the release liner 14 of
`the carrier sheet 12, and the reflective metal layer 18
`vacuum-deposited on the elastomeric film 16. Opacity
`for the laminate 36 is provided by the above-described
`opaque layer 26, for example. In this form of the inven-
`tion, a layer 38 of a primer material is coated over the
`opaque layer 26. The primer coat can be any material
`which bonds to the opaque layer 26, provides improved
`adherence between the laminate 36 and a substrate to
`which it is bonded, and has some degree of elasticity or
`flexibility. For example,
`if the laminate 36 is being
`bonded to a substrate made from urethane rubber, the
`primer layer 38 is desirably a material which is compati-
`ble with the urethane rubber and will become integrally
`bonded with it. A typical material for the primer layer
`is a permanently thermoplastic coating such as a poly-
`urethane coating. Several other primers, or adhesives,
`applicable to elastomeric surfaces include natural rub-
`ber type adhesives, a thin vinyl coating used as a heat
`seal adhesive, and styrene butadiene rubber adhesives.
`FIGS. 6 and 7 show a preferred means for integrally
`bonding the laminate 36 to an injection-molded article.
`The injection-molding machine includes a female mold
`40 and a movable male mold 42. The female mold in-
`cludes a recess which holds a die 44 having a mold
`surface in the reverse configuration of the article to be
`molded. The laminate 36 is initially placed across the
`mold surface of the die 44 and then the male mold 42 is
`forced into pressure contact with the outer edges of the
`laminate and the female mold to form a mold cavity 45.
`A heated plastic molding compound, which in this in-
`stance is urethane rubber, is forced into the mold cavity
`through a passageway 46 under high pressure against
`the primer layer 38 on the reverse face of the laminate
`36. This stretches the laminate and forces it further into
`the mold cavity under relatively high pressure so that it
`conforms to the shape of the mold surface in the die 44.
`The result is a molded urethane rubber article 48 having
`an elastomeric reflective metal surface. The male mold
`42 then is retracted, and the excess material, or sprue,
`shown at 49 is removed. The molded rubber article 48 is
`then separated from the mold cavity and the carrier
`sheet 12 is stripped from the face of the article.
`A major use for the molded article 48 of this inven-
`tion is in the elastomeric molded rubber bumpers used
`today in late-model automobiles. The molded article 48
`can be an injection-molded automobile bumper made
`from urethane rubber, for example, having the elasto-
`meric reflective metal laminate bonded to its front sur-
`face. The preferred metal layer is a highly reflective
`corrosion and abrasion-resistant metal, such as chro-
`mium or Nichrome. The vacuum-deposited metal layer
`is protected by the outer coating provided by the elasto-
`
`Wavelock
`Exhibit1003
`Page6
`(cid:58)(cid:68)(cid:89)(cid:72)(cid:79)(cid:82)(cid:70)(cid:78)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:40)(cid:91)(cid:75)(cid:76)(cid:69)(cid:76)(cid:87)(cid:3)(cid:20)(cid:19)(cid:19)(cid:27)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:51)(cid:68)(cid:74)(cid:72)(cid:3)(cid:25)
`
`

`
`4,101,698
`
`8
`pressure of the molding operation. The molded article
`56 is then separate from the mold cavity. The article 56
`can serve as a variety of molded articles with reflective
`metal finishes, such as an impact-absorbing bumper for
`automobiles.
`We claim:
`
`7
`meric film 16, which is preferably a transparent poly-
`urethane film. When used as an impact-absorbing bum-
`per for automobiles, the article 48 overcomes the objec-
`tions to metal chrome-plated bumpers, such as their
`greater weight, reduced resistance to impact damage,
`and greater susceptibility to corrosion.
`The article shown in FIG. 4 also can be injection-
`molded in much the same way as shown in FIGS. 6 and
`7. In this instance, the adhesive layer 20 can be replaced
`with a primer layer which is compatible with the mate-
`rial from which the laminate and the molded article are
`made to control the bond between the injection-molded
`plastic and the metal or opaque layer of the laminate.
`Typical primer layers include thermoplastic polyure-
`thane, ABS, or acrylic coatings, or Union Carbide’s
`VMCH vinyl resin.
`FIG. 8 shows an elastomeric laminate 50 in the form
`of a hot transfer sheet. Hot transfer sheets, or “hot
`stamp tape,” is known in the decorative laminate art,
`and a typical hot stamp tape is disclosed in U.S. Pat. No.
`3,666,516 to Dunning and owned by the assignee of this
`application. The hot transfer sheet 50 includes a trans-
`parent elastomeric film 16 coated onto a release layer 51
`coated on the carrier sheet 12. The reflective metal
`layer 18 is vacuum-deposited onto the elastomeric film
`16. Opacity for the laminate S0 is provided by the
`opaque layer 26, which can be in any of the forms de-
`scribed above. The layer 38 of primer is coated over the
`opaque layer 26 to improve the adherence between the
`laminate 50 and a substrate to which it is bonded.
`The release coating 51 may be a wax or paraffin-
`based release coating which melts or softens at a tem-
`perature below that of the other layers in the laminate
`so that neither the carrier 12, nor the remainder of the
`laminate which is releasably attachable to the carrier, is
`melted or softened under the temperatures produced by
`the molding operation shown in FIGS. 9 or 10. The
`exception is that the surface of the primer layer 38 adja-
`cent the substrate may be sufficiently softened or made
`sufficiently tacky to provide adherence to the substrate
`during the molding operation. A variety of release coats
`for such a hot transfer sheet can be used, and examples
`of typical release coats are shown in the Dunning U.S.
`Pat. No. 3,666,516 referred to above.
`FIGS. 9 and 10 show a preferred means for integrally
`bonding the hot transfer sheet 50 to an injection-molded
`article. In FIGS. 9 and 10 the laminate S0 is represented
`schematically as a carrier layer 52 comprising the car-
`rier 12 and the release coat 51, and a transferably deco-
`rative layer 54 which includes the transparent outer
`elastomeric sheet 16, the metallized layer 18, the opaque
`layer 26, and the primer layer 38. The laminate 50 is
`initially placed across the mold surface of the die 44,
`and the mold is forced into contact with the outer edges
`of the laminate and the female mold to form the mold
`cavity 45 in a manner identical to that described above
`in FIGS. 6 and 7. A heated plastic molding compound,
`such as urethane rubber, is forced under pressure into
`the mold cavity and against the reverse face of the
`laminate 50. The pressure of the injected molding com-
`pound stretches the laminate and forces it further into
`the mold cavity under relatively high pressure to con-
`form to the shape of the mold surface in the die 44. The
`heat from the molding operation also is sufficiently high
`to melt or soften the release coating 51 so that when the
`male mold 42 is retracted, the carrier layer 52 releases
`from the transferable layer 54 which bonds to the front
`surface of the molded article in response to the heat and
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`45
`
`50
`
`55
`
`65
`
`1. A laminate for transferring a decorative metallized
`finish to a substrate comprising a substantially transpar-
`ent, flexible and foldable, self-supporting elastomeric
`film of polyurethane material; a reflective metal layer
`bonded to a surface of the elastomeric film in micro-
`scopically discontinuous quantities in an amount which
`forms an apparent optically continuous reflective sur-
`face and which is elastically deformable in response to
`corresponding deformation of the elastomeric film; and
`an adherence layer on the side of the metal layer oppo-
`site the elastomeric film for adherently attaching the
`metal layer to a substrate so the elastomeric film pro-
`vides a protective outer covering for the adherently
`attached reflective metal layer.
`2. A laminate according to claim 1 in which the re-
`flective metal layer is selected from the group consist-
`ing of chromium and alloys of chromium.
`3. A laminate according to claim 1 in which the re-
`flective metal layer is selected from the group consist-
`ing of chromium; nickel; alloys of chromium and nickel;
`alloys of chromium and iron; alloys of iron, nickel and
`chromium; aluminum; alloys of aluminum; antimony;
`tin; magnesium; indium; platinum; silver; rhodium; and
`palladium.
`4. A laminate according to claim 1 including an
`opaque layer on a side of the reflective metal layer
`opposite the elastomeric film for reinforcing the opacity
`of the metal layer.
`5. A laminate according to claim 4 in which the
`opaque layer is a substantially elastomeric layer of metal
`flakes.
`6. A laminate according to claim 4 in which the
`opaque layer includes a stretchable layer of pigment
`material.
`7. A laminate according to claim 4 in which the re-
`flective metal layer is selected from the group consist-
`ing of chromium; nickel; alloys of chromium and nickel;
`alloys of chromium and iron; alloys of iron, nickel and
`chromium; aluminum; alloys of aluminum; antimony;
`tin; magnesium; indium; platinum; silver; rhodium; and
`palladium.
`8. A laminate for transferring a decorative metallized
`finish to a substrate comprising a substantially transpar-
`ent, flexible and foldable, self-supporting elastomeric
`film of polyurethane material; a reflective metal layer
`bonded to a surface of the polyurethane film in micro-
`scopically discontinuous quantities in an amount which
`forms an apparent