HllllHllllllllllllllIlllllllllllllllllllNIHll!!!IIIIIIHIIHIIIIIIHIII
`US005532045A
`
`United States Patent
`
`[191
`
`Wade
`
`[11]
`
`Patent Number:
`
`5,532,045
`
`[45] Date of Patent:
`
`Jul. 2, 1996
`
`
`
`. .... 156/659
`......
`8/1983 Beckett
`..... .. 428/31
`5/1984 Waugh . ... ...
`156/345
`5/1985 Beckett
`..
`10/1989 Yaver ...................................... .. 428/31
`
`4,398,994
`4,446,179
`4,517,045
`4,877,657
`
`Primary Examz'ner—Patrick J. Ryan
`Assistant Examiner—Abraham Bahta
`Attorney, Agent, or Firm~St. Onge Steward Johnston &
`Reens
`
`[57]
`
`ABSTRACT
`
`A process for preparing a part for a vehicle, the part having
`a weather sealed mirror finish decorative portion integral
`therewith is presented. The inventive process includes the
`steps of providing a sheet of relatively clear, weather resis~
`tant polymeric material having two surfaces, an external
`surface and an internal surface; providing a sheet of a
`forrnable substrate material having a internal surface and an
`external surface; metallizing a portion of at least one of the
`internal surfaces of the polymeric material and the substrate
`material, such that metallization is contained within the edge
`of the metallized material; adhering the internal surface of
`the substrate material to the internal surface of the polymeric
`material such that the metallization is disposed between the
`polymeric material and the substrate material
`to form a
`sandwich; and forming the sandwich into a vehicle part
`having a weather sealed mirror finish decorative portion.
`
`[54 VEHICLE PART HAVING WEATHER
`SEALED MIRROR FINISH DECORATIVE
`PORTION INTEGRAL THEREWITH
`
`[75
`
`Inventor: Linwood E. Wade, Weston, Conn.
`
`[73
`
`Assignee: Hicks & Otis Prints, Inc., Norwalk,
`Conn.
`
`[2l‘ Appl. No.: 429,518
`
`[22
`
`Filed:
`
`Apr. 26, 1995
`
`Related U.S. Application Data
`
`[62
`
`Division of Ser. No. 204,769, Mar. 2, 1994.
`
`Int. Cl.5 ........................................................ B32B 9/00
`[51
`[52 U.S. Cl.
`.............................. 428/187; 428/31; 428/43;
`428/67; 428/133; 428/192; 428/204; 428/327;
`428/463; 428/516; 428/518; 293/128
`Field of Search .................................. 428/31, 43, 67,
`428/133, 187, 192, 204, 327, 463, 516,
`518, 40, 205, 131, 78, 340; 293/128
`
`[58
`
`[56]
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`3,811,989
`4,351,864
`
`5/1974 Heam ........................................ .. 161/5
`9/1982 Giannakidis ............................ .. 428/31
`
`21 Claims, 2 Drawing Sheets
`
`
`
`Wavelock
`Exhibit1011
`Page1
`(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:20)(cid:20)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:51)(cid:68)(cid:74)(cid:72)(cid:3)(cid:20)
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`

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`U.S. Patent
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`Jul. 2, 1996
`
`Sheet 1 of 2
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`5,532,045
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`26 94
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`F/G. /
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`30
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`22
`2{6
`rzjg;--'----------'vIzr.1r.
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`40 m.“.‘“..“““““
`44}
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`20
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`P76. 2
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`Wavelock
`Exhibit1011
`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:20)(cid:20)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:51)(cid:68)(cid:74)(cid:72)(cid:3)(cid:21)
`
`

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`U.S. Patent
`
`Jul. 2, 1996
`
`Sheet 2 of 2
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`5,532,045
`
`Wavelock
`Exhibit1011
`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:20)(cid:20)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:51)(cid:68)(cid:74)(cid:72)(cid:3)(cid:22)
`
`

`
`1
`VEHICLE PART HAVING WEATHER
`SEALED MIRROR FINISH DECORATIVE
`PORTION INTEGRAL THEREWITH
`
`This is a divisional of copending application(s) Ser. No.
`08/204,769 filed on 3/2/94.
`
`TECHNICAL FIELD
`
`The present invention relates to a vehicle part, especially
`a trim part for an automobile or truck body, having a weather
`sealed mirror finish decorative portion integral therewith.
`Also included is a process for preparing such part.
`Chrome plated trim has long been an important feature of
`both the exterior and interior of automobiles, trucks and
`other vehicles. The durable mirror finish provided by
`‘chrome, which is capable of producing a clear reflected
`image, has over time become more expensive and commer-
`cially disadvantageous, largely because of ecological restric-
`tions on chromium.
`
`One widely used alternative to chrome finishes is a
`polyester film having aluminum metallized thereon and
`protected from weathering with a clear extruded vinyl or
`fluoropolymer film. Since the aluminum layer is typically
`extremely thin, it is subject to attack by moisture, salt and
`other materials to which it can be exposed, especially on the
`exterior of a vehicle. Because of this it is essential that the
`edges of a metallized aluminum layer be protected from
`attack. Commonly this is done by embedding the edges
`while extruding the base to which it is bonded, and then
`protecting cut ends with protective sealers. This approach is
`extremely labor intensive. In addition, although it has been
`somewhat successful, such an approach cannot be extended
`to the use of a metallized film for other manufacturing
`techniques. As a result, the parts produced must be linear and
`provision must be made in the manufacturing process for
`sealing the edges.
`Currently, requirements for vehicle trim combine mirror
`finish elements with colors, graphics (such as logos or short
`words or acronyms) and “end caps”—injection molded
`terminations to beautify cut ends. Generally, because of the
`limitations of current manufacturing processes, each of these
`features is incorporated into separate parts which must be
`joined together to form the finished article. Each part must
`be individually protected and the schemes to join them
`together are complex. Accordingly, the production of such
`parts is very labor intensive and expensive.
`What is desired, therefore, is a vehicular trim piece with
`an integrated decorative finish combining a good distinction
`of image with a variety of different shapes, along with colors
`and/or graphics.
`
`BACKGROUND ART
`
`As noted above there have been various attempts to
`produce a less labor intensive yet desirably decorative trim
`piece for vehicles. Such attempts can be seen in the prior art,
`such as in Hearn, U.S. Pat. No. 3,811,989, which discloses
`a decorative trim strip comprising a substrate having a metal
`or metallized strip bonded thereto and a layer of clear plastic
`material covering the metal or metallized strip. Similarly,
`Giannakidis, in U.S. Pat. No. 4,351,864, discloses a molding
`having a glazed structure where a bright film is metallized on
`both sides and then encapsulated in an ionomer resin mate-
`rial. In U.S. Pat. No. 4,446,179, Waugh discloses a trim strip
`having a decorative surface fonned in a longitudinal channel
`
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`5,532,045
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`of a molding. An impact resistant plastic overlay is then laid
`over the decorative surface.
`
`In a more recent improvement described in U.S. Pat. No.
`4,877,657, Yaver teaches the production of a flexible trim
`strip which includes a transparent or translucent core having
`a bottom surface covered with a opaque layer and a top
`surface having a thin covering of a metal. A transparent
`plastic overlay’is then applied over the top covering of the
`metal.
`
`Unfortunately, nothing in the prior art permits the pro-
`duction of a trim material having a mirror finish image of
`varying shapes thereon where the image is sufiiciently
`protected from the weather.
`SUMMARY OF INVENTION
`
`Itis an object of the present invention to provide a part for
`a Vehicle, be it exterior or interior, having a weather sealed
`mirror finish decorative portion integral therewith.
`It is another object of the invention to provide such a part
`where the mirror finish decorative portion has excellent
`distinction of image yet is protected from damage occa-
`sioned by exposure to the elements.
`'
`It is yet another object of the invention to provide such a
`vehicle part where the decorative portion can assume a
`variety of different shapes while maintaining its protection
`from the elements.
`
`It is still another objective of the invention to provide a
`vehicle trim part having a mirror finish decorative portion
`integral therewith which can further be provided with dif-
`ferent colors and/or graphic designs to match interior or
`exterior colors of the vehicle.
`
`It is another object of the invention to provide such a
`vehicle part which includes graphics which are either inde-
`pendent of or complementary to the weather sealed rrrirror
`finished decorative portion to provide a desired appearance
`to the vehicle part.
`It is a further object of the invention to provide a process
`for producing such vehicle parts.
`These and other objects of the invention can be achieved
`by the provision of a vehicle part which is comprised of a
`sheet of relatively clear weather resistant polymeric material
`and a sheet of a forrnable substrate material, where a portion
`of at least one of the surfaces of the polymeric material or
`the substrate material is metallized in a desired pattern. The
`polymeric material and the substrate material are then
`adhered to each other, such that the metallization is disposed
`between the polymeric material and the substrate material to
`form a sandwich where the metallization is contained within
`the edge of the sandwich.
`In an alternate embodiment, the vehicle part can comprise
`a sheet of a relatively clear weather resistant polymeric
`material having a portion of one of its surfaces metallized in
`a desired pattern such that the metallization is contained
`within the edges of the polymeric material. The metallized
`polymeric material is then adhered to a shaped polymeric
`material such that the metallization is sandwiched between
`the first polymeric material and the pre-shaped polymeric
`material, in order to form a vehicle part.
`Other objects, aspects and features of the present inven-
`tion, in addition to those mentioned above, will be under-
`stood from the following detailed description, provided in
`conjunction with the accompanying drawings.
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a partially delaminated perspective view of
`metallized and adhesive coated polymeric material and
`
`Wavelock
`Exhibit 1011
`Page 4
`(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:20)(cid:20)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:51)(cid:68)(cid:74)(cid:72)(cid:3)(cid:23)
`
`

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`5,532,045
`
`3
`substrate material in accordance with the present invention;
`FIG. 2 is a cross-sectional view along lines -2—2- of the
`embodiment of FIG. 1;
`FIG. 3 is a cut-away perspective view of a finished part in
`accordance with the present invention;
`FIG. 4 is an end view of the part of FIG. 2;
`FIG. 5 is a cut-away perspective view of a finished part in
`accordance with the present invention, having a backing
`material applied thereto;
`FIG. 6 is an end view of the part of FIG. 5;
`FIG. 7 is a partially delarninated perspective view of
`metallized polymeric material in accordance with an alter-
`nate embodiment of the present invention;
`FIG. 8 is a cut-away perspective view of a finished part
`formed from the embodiment of FIG. 7; and
`FIG. 9 is an end view of the part of FIG. 8.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENT
`
`Referring now to FIGS. 1-9 where like elements are
`identified by like numbers in the drawings, a process is
`presented for preparing a vehicle trim part 10, which is
`suitable for use as trim on the exterior or interior of a
`vehicle. The terms “front”, “back”, “top”, “bottom”, etc. as
`used herein shall refer to part 10 when in the orientation
`illustrated in FIG. 1. However, it will be understood that this
`is for convenience only and part 10 can assume various
`orientations when installed in or on a vehicle.
`
`Additionally, for convenience, this description shall refer
`to an automobile or a car. However, it will be understood that
`part 10 can be used on any vehicle,
`including trucks,
`recreational vehicles, utility vehicles, off-road vehicles, etc.
`Refering new to FIG. 1, the inventive process begins with
`the provision of a sheet of relatively clear weather resistant
`polymeric material 20, which has two surfaces, denoted an
`external surface 22 (the top surface in the orientation illus-
`trated in FIG. 1) and an internal surface 24 (the bottom
`surface in the orientation illustrated in FIG. 1). The sheet of
`polymeric material 20 can comprise a continuous web of
`material which is cut before or after treatment into the
`
`appropriate lengths. Alternatively, sheet of polymeric mate-
`rial 20 can be individual sheets or it can have the shape of
`part 10 as finished, prior to further processing. Commonly,
`sheet of polymeric material 20 is a continuous web which,
`after metallization and further treatment as described here-
`inbelow, is cut into the appropriate lengths and cut to the
`proper shape. Desirably, polymeric material is maintained as
`a continuous web as long as possible prior to cutting, to
`facilitate handling.
`Sheet of polymeric material 20 can be made of any
`polymeric film material which has the weatherability and
`resistance to staining or discoloration when exposed to
`fluids, salt, gas, cleaners, etc. so as to remain clear in the
`environment to which it is to be exposed, such as the
`external areas of a car. Areas of polymeric material 20 can
`be texturized, etc., and do not necessarily have to remain
`smooth. The clarity, resistance to staining and discoloration
`and texture of polymeric material 20 should be suflicient to
`maintain good distinction of image of the mirror finish
`material described hereinbelow when viewed through poly-
`meric material 20.
`
`The polymeric material 20, otherwise commonly referred
`to as a “clear coat”, can be any polymeric material having
`the noted properties. Typically, the material is a fluoropoly-
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`mer or vinyl polymer film, which can be compounded with
`agents such as antioxidants and ultraviolet
`light
`(UV)
`absorbers. Two typical polymeric material useful herein are
`a polyvinylidene fluoride (PVDF) film and an unoriented
`polyvinyl fluoride (PVF) film commercially available under
`the trade name SP Tedlar from DuPont DeNemours Com-
`pany of Wilmington, Del.
`In addition, polymeric material 20 can comprise other
`polymeric materials such as polyethyltetrafluoroethylene,
`acrylic, polyurethane, polycarbonate, polyester, melamine,
`urea formaldehyde, polyvinylchloride, silicone, silica or
`mixtures of any of the above. These polymers can be clear
`or tinted. Moreover, multilayer coatings such as polyvinyl-
`chloride with acrylic overlayer, can be employed as poly-
`meric material 20.
`
`The thickness of polymeric material 20 should be that
`sufficient to protect underlying layers from the elements,
`especially weather. Typically, polymeric material 20 need
`only have a thickness of at least about 0.3 mils, and can be
`as thick as about 10 mils. If polymeric material 20 is a vinyl
`polymer film, and not a fluoropolymer film, it should have
`a thickness of at least about 5 mils and is generally about 5
`to about 30 rrrils thick.
`
`The polymeric material 20 is then metallized as shown in
`FIG. 1, that is a layer of metal 26 is applied to internal
`surface 24 of polymeric material 20. The surface to which
`the layer of metal 26 is applied is referred to as internal
`surface 24 of polymeric material 20, since this surface shall
`be an internal surface of vehicle part 10. The remaining
`surface is denoted external surface 22, since it is on the
`external portion of vehicle part 10.
`Metallization can be performed by any of a wide variety
`of methods. For instance, metallization can be applied by
`sputtering, vapor deposition, ion beam deposition or chemi-
`cal vapor deposition.
`One advantageous method of metallizing sheet of poly-
`meric material 20 involves forrning_a coating of a metal on
`internal surface 24 by directing a stream of metal vapor or
`atoms onto the surface by a vacuum deposition technique.
`This can be effected by heating the metal in a high vacuum,
`preferably in the range of about l0‘3 to about 102 torr, to
`a temperature above its melting point, such that the vapor
`pressure of the metal exceeds about l0‘2 torr. It can also be
`effected by subjecting the metal to a stream of bombarding
`ions whereby the metal is removed by mass transfer “sput-
`tering”. When these conditions are achieved, the metal is
`vaporized or sputtered, emitting metal vapor or atoms in all
`directions. These vapors or atoms impinge on the internal
`surface 24 of polymeric material 20, condense, and thereby
`form a thin metallic coating on polymeric material 20.
`It may be useful, prior to metallization, to prepare internal
`surface 24 of polymeric material 20 to promote adhesion of
`the metal thereto. This can be done by first coating internal
`surface 24 with a material which will promote adhesion, or
`by treating internal surface 24 in a manner which will
`promote adhesion.
`Most commonly, the metal used to form metal layer 26 is
`aluminum, although other metals can be used depending on
`the desired appearance of the resulting mirror finish deco-
`rative portion 26a of part 10. When aluminum is the metal,
`the thickness of metal layer 26 should be at least about 75
`angstroms, and can range as high as about 275 angstroms.
`Thicknesses up to about 3000 angstroms may be desirable in
`some cases. For other metals, other thicknesses may be
`desirable.
`As noted above and illustrated with reference to FIGS. 3
`
`and 4, internal surface 24 of sheet of polymeric material 20
`Wavelock
`Exhibit1011
`Page5
`(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:20)(cid:20)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:51)(cid:68)(cid:74)(cid:72)(cid:3)(cid:24)
`
`

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`5,532,045
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`5
`is metallized in a desired pattern. This can be accomplished
`by providing a uniform coat of metal and then selectively
`demetallizing in a pattern. For instance, a protective physical
`or chemical mask can be applied over the desired pattern of
`metal layer 26 and the remaining, unprotected metal dis-
`solved by appropriate chemical or physical means.
`In addition, a chemical mask can be applied to internal
`surface 24 prior to metallization, which permits metal
`applied thereover to be rinsed or dissolved away by chemi-
`cal means, leaving the desired pattern. In another suitable
`method, a physical mask can be applied over internal surface
`24 prior to metalization, such that metallization occurs on
`internal surface 24 only in areas not covered by the physical
`mask; or the desired pattern can be produced by hot stamp-
`ing of a metallized transfer sheet having a release coating by
`aligning polymeric material 20 with the transfer sheet and
`then pressing on its back with a heated “shoe” in the desired
`pattern. Each of these methods of selectively demetallizing,
`or metallizing in a desired pattern, comprise conventional
`treatment processes which should be familiar to the skilled
`artisan.
`
`One especially advantageous means of providing metal-
`lization in a desired pattern on internal surface 24 is dis-
`closed by Beckett in U.S. Pat. No. 4,398,994, the disclosure
`of which is incorporated herein by reference. In the process
`disclosed by Beckett, a metallized film has a sodium hydrox-
`ide resistant material printed thereon in the desired pattern.
`The sodium hydroxide resistant material printed on the
`metallized layer is preferably a water insoluble resinous
`material, and it can be pigmented or clear. The non-printed
`metallized areas are then dissolved with a hot aqueous
`sodium hydroxide solution, which has a sodium hydroxide
`concentration of up to about 25%, to dissolve the unpro-
`tectcd metal yet leave the protected metallized areas undis-
`solved. In this manner, metallization in a variety of intricate
`patterns can be accomplished, as opposed to the linear
`metallization seen in the prior art.
`In metallizing internal surface 24 of sheet of polymeric
`material 20, care must be taken that metallization does not
`extend to the edge of the metallized material or more
`specifically to the edge of vehicle part 10 to be made from
`metallized material 20, as illustrated in FIG. 3, else protec-
`tion from the elements will not be complete.
`Optionally, a pattern or image can be printed on polymeric
`material 20 prior to metallization. This imprinting can be a
`logo or other desirable design, and can advantageously
`cooperate with the metallization to provide the impression of
`depth or to otherwise complement the mirror finish portion
`26a. Printing on polymeric material 20 can be by any means
`conventional in the art, such as by rotogravure or screen
`printing, as well as other methods within the skill of the
`artisan.
`
`Once polymeric material 20 is metallized in a desired
`pattern, an adhesive 30 is printed or coated across metallized
`polymeric material 20 in a preferred embodiment of the
`present invention illustrated in FIGS. 1-4. The nature of
`adhesive 30 depends on the nature of polymeric material 20
`and the substrate material to which polymeric material 20 is
`to be adhered. Generally, adhesive 30 can be a thermoplastic
`or cross-linked (with or without aid of an active or latent
`crosslinking agent) polyester, acrylic, polyarnid or urethane
`adhesive capable of preventing delarnination of vehicle part
`10 as well as polyvinylchloride or epoxy, or mixtures of any
`of the above.
`
`Advantageously, adhesive 30 is colored or pigmented, to
`match or complement either the interior or exterior colors of
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`the car. Diiferent pigments, such as metallic or pearlescent
`pigments, can be included in adhesive 30 in addition to
`rnicronized titanium oxide, fluorescent pigments or graphite.
`Additionally, other dye, coloring or pigment materials can
`be included to provide the desired color and appearance to
`vehicle part 10.
`to FIGS. 1-4, a sheet of a forrnable
`Referring still
`substrate material 40 is then provided, as either a continuous
`web, an individual sheet, or a sheet in the final shape of part
`10, as was the case with polymeric material 20. Formable
`substrate material 40 also has two surfaces, one denoted an
`internal surface 42 (the top surface in the orientation of FIG.
`1), and the other an external surface 44 (the bottom surface
`in the orientation of FIG. 1), with internal surface 42 being
`the surface which is adhered to polymeric material 20
`internal surface 24.
`
`Sheet of forrnable substrate material 40 is formed of any
`suitable material which is capable of being formed into a
`desired shape, is able to withstand further processing, and
`will adhere well to a backing material introduced behind it,
`when material is to be introduced behind it (as discussed in
`more detail hereinbelow). Typically substrate material 40
`comprises a polyolefin, a polyvinyl chloride or an acryloni-
`trile-butadiene-styrene copolymer. Other suitable materials
`include polypropylene,
`thermoplastic elastomers such as
`thermoplastic olefins or urethanes, polystyrene, polyure-
`thane, polycarbonate or mixtures of any of the above in
`single or multiple layers. The thickness of substrate material
`40 is generally at least about 1 mil and is more preferably
`between about 10 and about 30 mils, although thicker sheets
`are permissible.
`Sheet of substrate material 40 is laminated or otherwise
`adhered to polymeric material 20. Depending on the nature
`of adhesive 30, adhesive 30 can be cured merely by the
`application of pressure, by the application of heat and
`pressure, or through other means of curing adhesive 30 to
`prevent separation of substrate material 40 from polymeric
`material 20. Alternatively, polymeric material 20 can be
`extruded onto substrate material 40, or vice versa, eliminat-
`ing the need for adhesive 30.
`Once substrate material 40 and polymeric material 20 are
`adhered together,
`thereby completely sandwiching metal
`layer 26 therebetween, part 10 can be formed into its final
`three-dimensional shape.
`If polymeric material 20 and substrate material 40 are
`provided as continuous webs,
`they can be cut
`into the
`desired lengths and/or shapes either prior to or following
`formation into the final three-dimensional shape of part 10
`illustrated in FIGS. 3 and 4. As noted above, cutting is
`advantageously as late as possible to facilitate handling.
`The laminated sandwich of polymeric material 20 and
`substrate material 40 can be formed into the 3-dimensional
`shape of part 10 by any suitable technique such as vacuum
`forming, pressure-assisted forming, hydraulic molding or
`via the use of a silicone blanket and pressure. Once formed
`into the final shape of part 10, part 10 can be used as is or
`a backing rrraterial 50 such as a polyvinyl chloride, a
`polyolefin, an acrylonitrile-butadiene-styrene copolymer or
`a urethane can be molded into the rear of part 10 to provide
`support, as shown in FIGS. 5 and 6. This molding can be
`through injection or other types of molding, casting, or the
`use of a foaming material as would be familiar to the artisan.
`In an alternate embodiment of the present invention,
`substrate material 40 can be metallized in a desired pattern
`in place of polymeric material 20 (and by the same meth-
`ods). Polymeric material 20 can then be overlaid and
`
`Wavelock
`Exhibit 1011
`Page 6
`(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:20)(cid:20)(cid:3)(cid:3)(cid:3)(cid:3)(cid:3)(cid:51)(cid:68)(cid:74)(cid:72)(cid:3)(cid:25)
`
`

`
`5,532,045
`
`7
`adhered to substrate material 40, forming the sandwich
`described above. Although not as desirable, forming vehicle
`part 10 in this manner will provide an acceptably usable
`vehicle trim part.
`In still another alternative embodiment of the present
`invention illustrated in FIGS. 7-9, polymeric material 20
`can be metallized as described above and then coextruded
`with a pre-shaped polymeric material 60, such as an
`extruded polyvinyl chloride or other material backing pro-
`file. This can be performed as the backing profile exits an 10
`extruder or the metallized sheet of polymeric material 20 can
`be fed into a shoe with pre-shaped polymeric material 60,
`and fused or otherwise adhered thereto to form a finished
`vehicle part 10a.
`Finished vehicle part 10, when viewed from external
`surface 27 of polymeric material 20, should exhibit a mirror
`finish decorative portion 26:: which corresponds to the metal
`layer 26 sandwiched between polymeric material 20 and
`substrate material 40. This mirror finish should provide a
`high resolution reflection even when viewed through poly-
`meric material 20. The desired high mirror image reflection
`can be describe as a good distinction of image, which can be
`measured by comparison with the General Motors standard
`P9, used as a generally accepted standard for distinction of
`image.
`The present invention provides a vehicle part which has a
`weather sealed mirror finish decorative portion integral
`therewith. Since the metallized area is within the edges of
`vehicle part 10, and since polymeric material 20 and sub-
`strate material 40 are adhered together, potentially corrosive
`and other destructive elements are kept away from the metal
`layer 26. In this manner, many of the problems with con-
`ventional chrome or metallic finishes are avoided. In addi-
`tion, the process of the invention permits the mirror finish
`decorative portion to assume a wide variety of shapes,
`including logos, lettering, or other desirable graphic appear-
`ances, as opposed to the linear appearance of prior art
`metallized finishes.
`
`Moreover, because the mirror finish decorative portion is
`integral with vehicle part 10, vehicle part 10 is often more
`lightweight than its prior art counterparts, and requires fewer
`assembly steps, leading to significant savings.
`It is to be appreciated that the foregoing is illustrative and
`not limiting of the invention, and that various changes and
`modifications to the preferred embodiments described above
`will be apparent to those skilled in the art. Such changes and
`modifications can be made without departing from the spirit
`and scope of the present invention, and it is therefore
`intended that such changes and modifications be covered by
`the following claims.
`What is claimed is:
`1. A vehicle part having a weather sealed Inirror finish
`decorative portion integral therewith, comprising a sheet of
`relatively clear, weather resistant polymeric material having
`two surfaces, an external surface and an internal surface and
`a sheet of a formable substrate material having a internal
`surface and an external surface wherein a portion of at least
`one of the internal surfaces of the polymeric material and the
`substrate material being metallized in a desired pattern, such
`that metallization is contained within the edge of the met-
`allized material; the internal surface of the substrate material
`being adhered to the internal surface of the polymeric
`material such that the metallization is disposed between the
`polymeric material and the substrate material to form a
`sandwich; the sandwich being formed into a vehicle part
`having a weather sealed mirror finish decorative portion.
`
`8
`2. The vehicle part of claim 1 wherein the polymeric
`material comprises a sheet of a relatively weather and stain
`resistant polymeric material having a clarity suflicient to
`permit a good distinction of image of the metallization,
`5 when viewed through its external surface, and a thickness of
`between about 0.3 mil to about 10 mil.
`3. The vehicle part of claim 1 wherein the adhesive is
`colored.
`4. The vehicle part of claim 3 wherein the adhesive is
`colored to match or complement the exterior or interior
`colors of the vehicle.
`5. The vehicle part of claim 1 wherein the substrate
`material comprises a polyolefin, a polyvinyl chloride, an
`acrylonitrile-butadiene-styrene copolymer, polypropylene,
`polystyrene, polyurethane, polycarbonate, a thermoplastic
`15 olefin or urethane, or mixtures or layers thereof having a
`thickness of at least about 1 mil.
`6. A vehicle part having a weather sealed mirror finish
`decorative portion integral therewith, comprising a sheet of
`relatively clear, weather resistant first polymeric material
`having two surfaces, an external surface and an internal
`surface wherein a portion of the internal surface of the first
`polymeric material being metallized in a desired pattern,
`such that metallization is contained within the edge of the
`metallized material; the internal surface of the first poly-
`meric material being adhered to a shaped polymeric material
`such that the metallization is disposed between the first
`polymeric material and the shaped polymeric material to
`form a vehicle part having a weather sealed mirror finish
`decorative portion.
`7. The vehicle part of claim 6 wherein the first polymeric
`material comprises a sheet of a relatively weather and stain
`resistant polymeric material having a clarity suflicient to
`permit a good distinction of image of the metallization,
`when viewed through its external surface, and a thickness of
`between about 0.3 mil to about 10 mil.
`8. The vehicle part of claim 6 wherein the metallized first
`material is adhered to the shaped polymeric material via an
`adhesive, fusing the two polymeric materials together, or
`coextruding the two polymeric materials.
`9. The vehicle part of claim 8 wherein an adhesive is
`disposed between the internal surface of the first polymeric
`material and the shaped polymeric material.
`10. The vehicle part of claim 9 wherein the adhesive is
`colored.
`11. The vehicle part of claim 10 wherein the adhesive is
`colored to match or complement the exterior or interior
`colors of the vehicle.
`12. The vehicle part of claim 1 wherein the shaped
`polymeric material comprises a polyvinyl chloride, a poly-
`olefin, an acrylonitrile-butadiene-styrene copolymer, a ure-
`thane, or mixtures thereof.
`13. A process for preparing a part for a vehicle, the part
`having a weather sealed mirror finish decorative portion
`integral therewith, the process comprising:
`i. providing a sheet of relatively clear, weather resistant
`polymeric material having two surfaces, an internal
`surface and an external surface;
`ii. metallizing in a desired pattern a portion of the internal
`surface of the polymeric material to form a metallized
`polymeric material, provided the metallization does not
`extend to the edge of the metallized polymeric material;
`iii. adhering the internal surface of the metallized poly-
`meric material to a shaped polymeric material