Multiple applique process for injection molding articles
First Claim
1. A process for injection molding an article comprising the steps of:
- providing a first material including a first surface, a second surface opposite the first surface, a first edge, said first surface and said first edge forming a first corner edge;
providing a second material including a third surface, a fourth surface opposite the third surface, and a second edge, said third surface and said second edge forming a second corner edge;
abutting the first material against the second material with the first corner edge positioned immediately adjacent or contacting said second corner edge; and
injection molding a third material over the first material and the second material to form an article, wherein the third surface is in non-overlapping relation with respect to the second surface in the formed article.
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Accused Products
Abstract
A process for forming an injection molded article including multiple appliques. The process generally includes the steps of: positioning in a mold a first applique including a edge; positioning in the mold a second applique including a terminating end; abutting the second terminating end against the edge in a non-overlapping, substantially perpendicular configuration; injection molding a thermoplastic resin around the appliques to form an article. Because the first and second appliques do not overlap, they will not separate from one another over the life of the injection molded article. Accordingly, multiple applique articles formed according to the process of the present invention maintain their structural integrity and are resistant to warping, peeling and/or separation of the appliques from one another.
11 Citations
14 Claims
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1. A process for injection molding an article comprising the steps of:
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providing a first material including a first surface, a second surface opposite the first surface, a first edge, said first surface and said first edge forming a first corner edge;
providing a second material including a third surface, a fourth surface opposite the third surface, and a second edge, said third surface and said second edge forming a second corner edge;
abutting the first material against the second material with the first corner edge positioned immediately adjacent or contacting said second corner edge; and
injection molding a third material over the first material and the second material to form an article, wherein the third surface is in non-overlapping relation with respect to the second surface in the formed article. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A process for thermoforming an article comprising the steps of:
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providing a first applique including an edge, a first exposed surface and a first underside;
providing a second applique including an end, a second exposed surface and a second underside;
positioning the end proximate the edge, so that said second exposed surface abuts one portion of the edge and is at an angle to another portion of said edge;
molding a formable material over said first underside and said second underside wherein said second exposed surface abutting said edge prevents the formable material from escaping between the end and the edge; and
allowing the formable material to cure to form an article that resists deformation due to separation of the first and second appliques from one another over the useful life of the article. - View Dependent Claims (10, 11, 12)
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13. A process for forming an article having at least two appliques including the steps of:
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positioning a first applique of a depth and including a first terminating end in a mold;
abutting a second applique adjacent the first terminating end so that a portion of the second applique extends beyond the first terminating end; and
injection molding a material into the mold over the first and second appliques to form an article, wherein the portion of the applique extending beyond the first terminating end at least partially melts to form at least one melted finger in the material.
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14. A process for injection molding an article comprising the steps of:
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providing a first material including a first surface, a second surface opposite the first surface and a first edge, said second surface and said first edge forming a first corner edge;
providing a second material including a third surface, a fourth surface opposite the third surface, and a second edge, said third surface and said second edge forming a second corner edge;
abutting the first material against the second material with the first corner edge positioned immediately adjacent or contacting said second corner edge; and
injection molding a third material over the first material and the second material to form an article, wherein the third surface is in non-overlapping relation with respect to the second surface in the formed article and said second corner edge is separated a distance from said second surface.
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Specification