METHOD FOR MAKING A DECORATIVE PLASTIC LAMINATE

• US 3,668,034 A
• Filed: 08/05/1970
• Issued: 06/06/1972
• Est. Priority Date: 08/05/1970
• Status: Expired due to Term

• Current Assignee: Leon Plastics, Inc.
• Original Assignee: Arthur S. Nicholas, Sarkis M. Kassouni
• Inventors: Nicholas, Arthur S., Kassouni, Sarkis M.
• Primary Examiner(s): Padgett, Benjamin R.
• Assistant Examiner(s): Lechert, Jr., Stephen J.
• Application Number:
  US05/061,215
• Time in Patent Office: 671 Days
• Field of Search: 156/242,245,306,309
• US Class Current: 264/241
• CPC Class Codes: B29C 45/14311 using means for bonding the coating to the articles B29C45/14795 takes precedence
• CPC Class Codes: B29C 45/14688 Coating articles provided with a decoration
• CPC Class Codes: B29C 45/14811 Multilayered articles B29C45/14827 takes precedence
• CPC Class Codes: B29K 2715/006 Glues or adhesives, e.g. hot melts or thermofusible adhesives
• CPC Class Codes: B29L 2009/008 metalized, galvanized
• CPC Class Codes: B32B 2038/0092 Metallizing
• CPC Class Codes: B32B 2255/205 Metallic coating
• CPC Class Codes: B32B 27/00 Layered products comprising a layer of synthetic resin fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B44C 3/04 Modelling plastic materials, e.g. clay
• CPC Class Codes: B44C 3/046 using a modelling surface, e.g. plate

Abstract

This disclosure relates to plastic laminates, preferably in the nature of an article, having an outer metalized layer, an intermediate bonding layer of a relatively low melting point, and a backing layer formed of a synthetic thermoplastic material whose melting point is at least as high and preferably higher than the melting point of the intermediate layer. The laminate is formed by bonding the outer metalized layer to the intermediate layer, preferably by heat fusion, placing the laminate of the metalized layer and the intermediate layer into a mold and injecting the backing material into the mold to form an article and to bond the backing material to the intermediate layer.

Claims

2. A process for making an article having a decorative metalized film on at least a portion of the surface comprising:

laminating a thin film of a synthetic heat softenable organic material onto a first surface of said metalized film;

placing at least a portion of said laminated film into a mold cavity with the opposite said laminated first surface against a side of the mold cavity and with said laminated first surface exposed to the interior of said mold cavity; and

injecting into said Mold cavity at a high temperature and pressure, a flowable synthetic organic material having a melting point at least as high as the melting point of said synthetic heat softenable organic film which is laminated to said metalized film.

3. A process according to claim 2 wherein said mold cavity has a grainy surface and a grainy surface is formed on said metalized film during the molding process.

4. A process according to claim 3 wherein said metalized layer is a high temperature thermoplastic material having a melting point above the melting point of said synthetic heat softenable organic film laminated to said metalized film and above the melting point of the flowable synthetic organic material injected into said mold cavity.

5. A process according to claim 4 wherein said high temperature metalized film is a polyester film having a melting point in the range of 480* to 510* F.

6. A process according to claim 5 wherein said synthetic heat softenable organic film bonded to said metalized film has a melting point in the range of 10* to 50* F. below said melting point of said flowable synthetic organic material injected into said mold cavity.

7. A process according to claim 6 wherein said synthetic heat softenable organic film bonded to said metalized film is a polymer of vinyl chloride.

8. A process according to claim 7 wherein said flowable synthetic organic material injected into said mold cavity is selected from the group consisting of vinyl polymers and copolymers thereof.

9. A process according to claim 7 wherein said flowable synthetic organic material injected into said mold cavity is a material selected from the group consisting of acrylonitrile-butadiene-stryene terpolymers and blends thereof.

10. A process according to claim 2 wherein said flowable synthetic organic material injected into said mold cavity is a material selected from the group consisting of vinyl polymers and copolymers thereof.

11. A process according to claim 2 wherein said flowable synthetic organic material injected into said mold cavity is a material selected from the group consisting of acrylonitrile-butadiene-stryene terpolymers and blends thereof.