In-mold lamination of decorative products

• US 7,981,342 B2
• Filed: 01/12/2009
• Issued: 07/19/2011
• Est. Priority Date: 12/31/2003
• Status: Expired due to Fees

• Current Assignee: International Automotive Components Group North America (Lear Corporation)
• Original Assignee: International Automotive Components Group North America (Lear Corporation)
• Inventors: Neitzke, Mark K., Hayes, Marc A., Cass, Michael W.
• Primary Examiner(s): HUSON, MONICA ANNE
• Application Number:
  US12/352,487
• Publication Number:
  US 20090174121A1
• Time in Patent Office: 918 Days
• Field of Search: None
• US Class Current: 264/241
• CPC Class Codes: B29C 45/1671 with an insert
• CPC Class Codes: B29C 45/1679 applying surface layers onto injection-moulded substrates inside the mould cavity, e.g. in-mould coating [IMC] applying suface layers after ejection B29C45/0053
• CPC Class Codes: B29L 2031/3008 Instrument panels
• CPC Class Codes: B29L 2031/3014 Door linings
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2307/4026 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/41 Opaque
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/416 Reflective
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/71 Resistive to light or to UV
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2479/00 Furniture upholstery B32B2601/00
• CPC Class Codes: B32B 2509/00 Household appliances
• CPC Class Codes: B32B 2605/08 Cars
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/10 : of paper or cardboard
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/286 : comprising polysulphones; polysulfides
• CPC Class Codes: B32B 27/302 : comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/308 : comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/325 : comprising polycycloolefins
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/365 : comprising polycarbonates
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 3/02 : characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: B32B 3/08 : characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric

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 thin foil, film, fabric or veneer. A method is also disclosed for coating the exposed surface of the decorative layer between injection of the backing and outer layers to impart a desired visual effect or repair the surface. Use of multiple layers of decorative film, clear plastic and colored/opaque plastic is also disclosed to provide distinguishing visual effects.

Claims

1. A method of forming an appliqué

or trim product including attachment features, comprising;

providing a first decorative layer having a front side and a back side;

injection molding a first plastic layer onto said back side of said first decorative layer;

solidifying said first plastic layer;

providing a second decorative layer having a front side and a back side;

injection molding a clear plastic transparent layer onto said front side of said first decorative layer and between said first and said second decorative layers,

solidifying said second clear transparent layer;

wherein said first plastic layer includes said attachment features for said appliqué

or trim panel,

wherein one of said first decorative layer and said second decorative layer includes a transparent portion, and

wherein said first and/or said second decorative layer comprises one or more of metal, wood, paper, cloth, a film, a foil, a laminate, a veneer, paint or fabric.

2. The method of claim 1 wherein said first plastic layer is colored or opaque or clear.

3. The method of claim 1 wherein said attachment features comprise one or more of hook and loop fasteners, molded bosses, molded Xmas tree projections, snap-fit surfaces, dielocks, undercuts and female features.

4. A method of forming an appliqué

or trim product including attachment features, comprising;

providing a first decorative layer having a front side and a back side;

injection molding a first clear plastic transparent layer onto said front side of said first decorative layer;

solidifying said first clear transparent layer;

injection molding a second clear plastic transparent layer onto said back side of said first decorative layer, providing an exposed surface of clear plastic;

wherein said second clear plastic transparent layer includes attachment features for attaching said appliqué

or trim panel;

solidifying said second clear transparent layer; and

spraying a coating of paint against said exposed surface of clear plastic,

wherein said coating of paint covers said attachment features for said appliqué

or trim panel,

wherein said attachment features comprise one or more of hook and loop fasteners, molded bosses, molded Xmas tree projections, snap-fit surfaces, dielocks, undercuts and female features, and

wherein said first decorative layer includes a transparent portion.

5. The method of claim 4 wherein said coating of paint is solidified by heat from the molding of said second clear plastic layer.

6. The method of claim 4 wherein said first decorative layer comprises one or more of metal, wood, paper, cloth, a film, a foil, a laminate, a veneer, paint or fabric.

7. The method of claim 4 wherein said coating of paint is solidified by exposure to radiation.

8. The method of claim 7 wherein said radiation is ultraviolet light.

9. A method of forming an appliqué

or trim product including attachment features, comprising;

providing a decorative layer having a front side and a back side;

injection molding a clear plastic transparent layer onto said back side of said first decorative layer, providing an exposed surface of clear plastic;

solidifying said clear transparent layer;

injection molding a colored or opaque plastic layer onto said exposed surface of clear plastic;

wherein said colored or opaque layer includes said attachment features for attaching said appliqué

or trim panel;

wherein said attachment features comprise one or more of hook and loop fasteners, molded bosses, molded Xmas tree projections, snap-fit surfaces, dielocks, undercuts and female features, and

solidifying said colored or opaque plastic layer;

wherein said colored or opaque plastic layer covers said attachment features for said appliqué

or trim panel, and

wherein said first decorative layer includes a transparent portion.

10. The method of claim 9 wherein the colored or opaque plastic layer comprises polycarbonate, acrylonitrile-butadiene-styrene or a combination thereof.

11. The method of claim 9 wherein said decorative layer comprises one or more of metal, wood, paper, cloth, a film, a foil, a laminate, a veneer, paint or fabric.

12. A method of forming an appliqué

or trim product including attachment features, comprising;

injection molding a colored or opaque plastic layer in a mold;

providing a decorative layer having a front side and a back side to said mold;

injection molding a clear plastic transparent layer between said back side of said first decorative layer and in front of said colored or opaque plastic layer;

wherein said colored or opaque plastic layer includes said attachment features for attaching said appliqué

or trim panel and covers said attachment features,

wherein said attachment features comprise one or more of hook and loop fasteners, molded bosses, molded Xmas tree projections, snap-fit surfaces, dielocks, undercuts and female features, and

wherein said first decorative layer includes a transparent portion, wherein said decorative layer comprises one or more of metal, wood, paper, cloth, a film, a foil, a laminate, a veneer, paint or fabric.