Process for producing an injected article that is decorated by flocking without using a flocking adhesive

• US 7,833,453 B2
• Filed: 11/23/2007
• Issued: 11/16/2010
• Est. Priority Date: 11/24/2006
• Status: Active Grant

• Current Assignee: Société d' Enduction Et de Flockage horaire
• Original Assignee: Société d' Enduction Et de Flockage horaire
• Inventors: Congard, Pierre Marie, Lion, Jean-Pierre
• Primary Examiner(s): Lee; Edmund H.
• Application Number:
  US11/944,496
• Publication Number:
  US 20080187706A1
• Time in Patent Office: 1,089 Days
• Field of Search: None
• US Class Current: 264/243
• CPC Class Codes: B29C 45/14016 Intermittently feeding endless articles, e.g. transfer films, to the mould B29C45/14262 takes precedence
• CPC Class Codes: B29C 45/14786 Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
• CPC Class Codes: B29C 45/14827 using a transfer foil detachable from the insert
• CPC Class Codes: B29K 2713/00 Use of textile products or fabrics for preformed parts, e.g. for inserts B29K2105/06 takes precedence
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: Y10T 428/23943 Flock surface

Abstract

Process for producing an injected article to which a flocked decoration is applied that includes the production of a flocked substrate (11) based on a temporary substrate (1) covered by a temporary adhesive (2) that keeps the flock fibers (3) in place, positioning of the flocked substrate in an injection mold of the article to be produced, injection of a polymer (12) being melted in the closed mold through an injection opening (4), removal of the injected article from the mold and the peeling off of the temporary substrate (1) and the temporary adhesive (2) from the injected article, characterized in that the flocked substrate (11) is positioned in the mold so that the flock fibers (3) are oriented toward the interior of the mold.

Claims

1. Process for producing an injected article to which a flocked decoration is applied, comprising the steps of:

forming a flocked substrate by covering a surface of a temporary substrate (1) with a temporary adhesive (2) that keeps flock fibers (3) in place with the temporary adhesive keeping the flock fibers (3) positioned transversely to the surface of the temporary substrate;

positioning the flocked substrate in an injection mold comprised of i) a first part perforated by an polymer injection opening, and ii) a second part onto which the temporary substrate of the flocked substrate is positioned and so that free ends of the flock fibers face the first part;

closing the injection mold; and

injecting a melted polymer (12) through the polymer injection opening of the closed mold and towards the free ends of the flock fibers thereby producing the injected article with the polymer deposited on the flocked substrate; and

removing the injected article from the mold and peeling off the temporary substrate (1) and the temporary adhesive (2) from the injected article so that the injected article has the flock fibers attached thereto.

2. Process for producing an injected article provided with a decoration by flocking according to claim 1, wherein the density of the flock fibers (3) is greater than one billion fibers per square meter.

3. Process for producing an injected article according to claim 1, wherein the temporary adhesive (2) is a thermosetting polymer.

4. Process for producing an injected article according to claim 3, wherein the temporary adhesive (2) is chosen in the family of silicone rubbers.

5. Process for producing an injected article according to claim 1, wherein the temporary substrate (1) is a polyester terephthalate film.

6. Process for producing an injected article according to claim 1, wherein the temporary substrate (1) is a non-woven substrate with polyester fibers or a paper substrate.

7. Process for producing an injected article according to claim 1, wherein the temporary substrate (1) can be heat-formed.

8. Process for producing an injected article according to claim 1, wherein the temporary substrate (1) can be deformed under the action of pressure.

9. Process for producing an injected article according to claim 1, wherein the temporary substrate (1) can be deformed by mechanical action.

10. Process for producing an injected article according to claim 1, wherein the flock fibers (3) are made of a polymer of the polyamide or polyester type.

11. Process for producing an injected article according to claim 1, wherein the flock fibers (3) are embossed before injection.

12. Process for producing an injected article according to claim 1, wherein the flock fibers (3) are imprinted by sublimation before injection.

13. Process for producing an injected article according to claim 1, wherein the flock fibers (3) and the injected polymer (12) are made of the same material.

14. Process for producing an injected article according to claim 13, wherein said fibers and said injected polymer are from the family of polyamide, polypropylene or polyester terephthalate.

15. Process for producing an injected article according to claim 2, wherein the temporary adhesive (2) is a thermosetting polymer.

16. Process for producing an injected article according to claim 2, wherein the temporary substrate (1) is a polyester terephthalate film.

17. Process for producing an injected article according to claim 3, wherein the temporary substrate (1) is a polyester terephthalate film.

18. Process for producing an injected article according to claim 4, wherein the temporary substrate (1) is a polyester terephthalate film.

19. Process for producing an injected article according to claim 2, wherein the temporary substrate (1) is a non-woven substrate with polyester fibers or a paper substrate.