Importance

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Abstract

Method and apparatus for forming thick wall plastic components laminated with formable decorative film layers. A thermoformable thick wall plastic sheet in the range of 0.065 to about 0.300 inches thick over at least half its area is provided having a thermoformable decorative dry film coating on one side forming an outer surface of the laminated sheet. The sheet is peripherally supported in an open center rack, heated in one or more ovens to forming temperature and formed by a combination of compression and, preferably, vacuum forming with subsequent trimming of excess material to form a finished component with a high quality finish suitable for automotive body use. The compression and vacuum forming steps may be interchangeably performed in order and provide for high quality finish on the outer surface with shaping of reentrant wall portions on the inner side. Any suitable form of laminated sheet may be formed by the apparatus and method. A preferred material is a laminated sheet with the decorative film covered with a thermoformable protective film which is retained during forming and protects the finished component until ready for service when it may be removed. To prevent finish marks due to compression forming, a removable outer protective coating or film may be used to protect the smoothness of the first protective layer and/or the decorative film coating until ready for forming when the outer film is removed.

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First Claim