An automotive quality paint coat is laminated to the exterior surface of a molded
plastic car body member or panel. In one embodiment, the paint coat includes an
exterior clear coat above a color coat. During processing, the clear coat and color
coat are each coated on a temporary flexible casting sheet and dried. A high gloss
surface is transferred to the clear coat from the casting sheet. The paint coat
is then transferred from the casting sheet to a thin, semi-flexible thermoformable
plastic backing sheet by dry paint transfer-laminating techniques. The resulting
laminate is thermoformed into a complex three-dimensional shape of the car body
member or panel. The preformed laminate is then bonded to an underlying plastic
substrate material, by injection-cladding techniques, for example, to form the
finished article. The paint coat has sufficient elongation to retain exterior automotive
appearance and durability properties during thermoforming without deglossing. The
backing sheet absorbs defects in the substrate material so the paint coat retains
its appearance and durability properties during the injection-cladding step. The
finished article comprises a high gloss, defect-free paint coat on the exterior
of a molded plastic car body member or panel. Solution-form polyvinylidene fluoride/acrylic
paint systems have remarkably high combined gloss and distinctiveness-of-image
levels, together with durability properties required for exterior automotive use.