IN MOLD LAMINATION OF DECORATIVE PRODUCTS
First Claim
1. A method for manufacturing an appliqué
- or trim panel having a decorative layer including a digitally printed image, a backing layer and an outer layer, comprising the steps of;
(a) providing a mold core and a mold cover which cooperate to form a cavity space wherein said core and cover are aligned along one or more shearing edges;
(b) providing a decorative layer, said decorative layer having a front side and a back side and including an image digitally printed on said front side;
(c) placing said decorative layer in said cavity space;
(d) aligning said mold core and said mold cover to form a first injection volume;
(e) injecting a first polymer against the back side of said decorative layer to substantially conform said decorative layer against the cover side of said first injection volume thereby forming a decorative composite comprising a backing layer at least partially formed behind said decorative layer;
(f) solidifying said backing layer;
(g) retracting said core and said decorative composite from said mold cover along said one or more shear edges by an amount related to the thickness of said outer layer thereby forming a second injection volume;
(h) injecting a second polymer into said second injection volume against the front side of said decorative composite to form an outer layer; and
(i) solidifying said second polymer to form said molded appliqué
or trim panel, wherein said second polymer is a clear plastic and wherein said decorative layer includes a metal foil, film, fabric, veneer, coating, laminate or paper substrate which is less than about 0.020 inches in thickness and has the front side decorated by a digital image from an inkjet printer.
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Accused Products
Abstract
A method of manufacturing decorative plastic composites having a decorative layer, a backing layer and a clear outer layer which provides exceptional “depth of image” is disclosed. Decorative or protective appliqués'"'"' having a wide range of decorative patterns may be formed by injection molding a backing layer behind and a clear outer layer on the top surface of a decorative layer, the decorative layer comprising a relatively thin metal foil, film, fabric, veneer or sheet of paper having a digital image from an inkjet printer deposited on a front surface thereof. In one exemplary embodiment, the appearance of a wood veneer may be modified by digitally printing a burl pattern over the wood grain surface of the veneer prior to injection molding.
90 Citations
26 Claims
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1. A method for manufacturing an appliqué
- or trim panel having a decorative layer including a digitally printed image, a backing layer and an outer layer, comprising the steps of;
(a) providing a mold core and a mold cover which cooperate to form a cavity space wherein said core and cover are aligned along one or more shearing edges; (b) providing a decorative layer, said decorative layer having a front side and a back side and including an image digitally printed on said front side; (c) placing said decorative layer in said cavity space; (d) aligning said mold core and said mold cover to form a first injection volume; (e) injecting a first polymer against the back side of said decorative layer to substantially conform said decorative layer against the cover side of said first injection volume thereby forming a decorative composite comprising a backing layer at least partially formed behind said decorative layer; (f) solidifying said backing layer; (g) retracting said core and said decorative composite from said mold cover along said one or more shear edges by an amount related to the thickness of said outer layer thereby forming a second injection volume; (h) injecting a second polymer into said second injection volume against the front side of said decorative composite to form an outer layer; and (i) solidifying said second polymer to form said molded appliqué
or trim panel, wherein said second polymer is a clear plastic and wherein said decorative layer includes a metal foil, film, fabric, veneer, coating, laminate or paper substrate which is less than about 0.020 inches in thickness and has the front side decorated by a digital image from an inkjet printer. - View Dependent Claims (2, 3, 4, 5, 6)
- or trim panel having a decorative layer including a digitally printed image, a backing layer and an outer layer, comprising the steps of;
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7. A method for manufacturing an appliqué
- or trim panel having a decorative layer having a digitally printed image, a backing layer and an outer layer, comprising the steps of;
(a) providing a mold core and a mold cover which cooperate to form a cavity space wherein said core and cover are aligned along one or more shearing edges; (b) providing a decorative layer, said decorative layer having a front side and a back side and including an image digitally printed on said front side; (c) placing said decorative layer in said cavity space; (d) aligning said mold core and said mold cover to form a first injection volume; (e) injecting a first polymer against the front side of said decorative layer to substantially conform said decorative layer against the core side of said first injection volume, thereby forming a decorative composite comprising an outer layer overlying said decorative layer; (f) solidifying said outer layer; (g) retracting said core along said one or more shear edges from said mold cover and said decorative composite by an amount equal to the thickness of said backing layer, thereby forming a second injection volume; (h) injecting a second polymer into said second injection volume against the backside of said decorative composite to form a backing layer; and (i) solidifying said second polymer to form a molded appliqué
or trim panel, wherein said first polymer is a clear plastic and wherein said decorative layer includes a metal foil, film, fabric, veneer, coating, laminate or paper substrate which is less than about 0.020 inches in thickness and has the front side decorated by digital printing using an inkjet printer. - View Dependent Claims (8, 9, 10, 11, 12)
- or trim panel having a decorative layer having a digitally printed image, a backing layer and an outer layer, comprising the steps of;
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13. A method for manufacturing an appliqué
- having a decorative layer having a digitally printed image, a backing layer and an outer layer, comprising the steps of;
(a) providing a mold core and mold cover which cooperate to form a cavity space; (b) providing a decorative layer, said decorative layer having a front side and a back side and including an image digitally printed on said front side; (c) placing said decorative layer in said cavity space; (d) aligning said mold core and said mold cover to form a first injection volume; (e) injecting a first polymer against the back side of said decorative layer to substantially conform said decorative layer against the cover side of said first injection volume thereby forming a decorative composite comprising a backing layer at least partially formed behind said decorative layer; (f) solidifying said backing layer; (g) retracting said core from said cover and removing said decorative composite; (h) providing a second mold core and second mold cover which cooperate to form a second cavity space; (i) placing said decorative composite upon said second mold core; (j) aligning said second mold cover and second mold core including said decorative composite to form a second injection volume; (k) injecting a second polymer into said second injection volume against the front side of said decorative composite to form an outer layer; and (l) solidifying said second polymer to form a molded appliqué
or trim panel, wherein said second polymer is a clear plastic and wherein said decorative layer includes a metal foil, film, fabric, veneer, coating, laminate or paper substrate which is less than about 0.020 inches in thickness and has the front side decorated by digital printing using an inkjet printer. - View Dependent Claims (14, 15, 17)
- having a decorative layer having a digitally printed image, a backing layer and an outer layer, comprising the steps of;
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16. A method for manufacturing a multi-layer composite product of injection molded plastic including a digitally printed image, comprising:
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(a) providing a moveable mold part comprising at least a first mold core; (b) providing a stationary mold part comprising at least a first mold cover including a first cavity and a second mold cover including a second mold cavity, the second cavity of greater volume than the first cavity; (c) providing a decorative layer, said decorative layer having a front side and a back side and including an image printed on said front side; (d) placing said decorative layer into said first cavity and aligning the first mold cover with the first mold core to form a first injection volume; (e) injecting a first polymeric material into said first injection volume behind said decorative layer to substantially conform said decorative layer against the cover side of said first injection volume thereby forming a decorative composite comprising a backing layer at least partially formed behind said decorative layer, and solidifying said first polymeric material to form a decorative composite; (f) sequentially moving said first mold core including said decorative composite with respect to said stationary mold part to selectively align said first mold core including said decorative composite with said second mold cover, said second mold cover and said first mold core including said decorative composite, forming a second injection volume; (g) injecting a second polymeric material into the second injection volume formed between said decorative composite and said second mold cover to form an outer layer, wherein said second polymeric material comprises a clear plastic; and (h) solidifying said second polymeric material to form a multi-layer composite product, wherein said decorative layer includes a metal foil, film, fabric, veneer, coating, laminate or paper substrate which is less than about 0.020 inches in thickness and has the front side decorated by digital printing using an inkjet printer. - View Dependent Claims (18)
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19. A method for manufacturing a multi-layer composite product of injection molded plastic including a digitally printed image, comprising:
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(a) providing a moveable mold part comprising at least a first mold cover including a first cavity; (b) providing a stationary mold part comprising at least a first mold core including a first projecting profile and a second mold core including a second projecting profile, the second profile smaller than the first profile; (c) providing a decorative layer, said decorative layer having a front side and a back side and including an image printed on said front side; (d) placing said decorative layer into said first cavity and aligning the first mold cover with the first mold core to form a first injection volume; (e) injecting a first polymeric material into said first injection volume between said decorative layer and said first mold cover to substantially conform said decorative layer against the core side of said first injection volume thereby forming a decorative composite comprising an outer layer at least partially formed on top of said decorative layer, and solidifying said first polymeric material to form a decorative composite, wherein said second polymeric material comprise a clear plastic; (f) sequentially moving said first mold cover including said decorative paper composite with respect to said stationary mold part to selectively align said first mold cover including said decorative composite with said second mold core, said second mold core and said first mold cover including said decorative composite forming a second injection volume; (g) injecting a second polymeric material into the second injection volume formed between said decorative composite and said second mold core to form a backing layer; and (h) solidifying said second polymeric material to form a multi-layer composite product, wherein said decorative layer includes a metal foil, film, fabric, veneer, coating, laminate or paper substrate which is less than about 0.020 inches in thickness and has the front side decorated by digital printing using an inkjet printer. - View Dependent Claims (20, 21)
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22. An appliqué
- '"'"' or trim panel for decorating or protecting a surface and including a digitally printed image, comprising;
a decorative layer including a front side and a back side and including a printed image printed on said front side, wherein said decorative layer includes a metal foil, film, fabric, veneer, coating, laminate or paper substrate which is less than about 0.020 inches in thickness and having the front side decorated by digital printing using an inkjet printer; an injection molded plastic backing layer on said back side; and an injection molded plastic outer layer on said front side, wherein said outer layer comprises a clear plastic, said outer layer having a thickness in the range of about 0.5-2.0 mm. - View Dependent Claims (23, 24, 25)
- '"'"' or trim panel for decorating or protecting a surface and including a digitally printed image, comprising;
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26. A method for the in-line production of an appliqué
- or trim component having a decorative layer having a digitally printed image, a molded backing layer and a molded outer layer, comprising the steps of;
(a) providing an inkjet printer adjacent to a plastic molding press; (b) providing a substrate, said substrate including a metal foil, film, fabric, veneer, coating, laminate or paper substrate which is less than about 0.020 inches in thickness, said substrate including a front and a back side; (c) advancing said substrate through said printer whereby droplets of ink are deposited from one or more printheads in said printer onto said front side of said substrate, said droplets deposited in such a pattern so as to create a digitally printed image; (d) drying said ink droplets; (e) expelling said substrate from said printer, (f) trimming said substrate to shape to form a decorative layer; (g) providing a mold core and a mold cover which cooperate to form a cavity space wherein said core and cover are aligned along one or more shearing edges; (h) placing said decorative layer in said cavity space; (i) aligning said mold core and said mold cover to form a first injection volume; (j) injecting a first polymer against the backside of said decorative layer to substantially conform said decorative layer against the cover side of said first injection volume thereby forming a decorative composite comprising a backing layer at least partially formed behind said decorative layer; (k) solidifying said backing layer; (l) retracting said core and said decorative paper composite from said mold cover along said one or more shear edges by an amount related to the thickness of said outer layer thereby forming a second injection volume; (m) injecting a second polymer into said second injection volume against the front side of said decorative composite to form an outer layer; and (n) solidifying said second polymer to form said molded appliqué
or trim panel wherein said outer layer comprises a clear plastic, said outer layer having a thickness in the range of about 0.5-2.0 mm.
- or trim component having a decorative layer having a digitally printed image, a molded backing layer and a molded outer layer, comprising the steps of;
Specification