In mold lamination of decorative products

• US 8,071,000 B2
• Filed: 03/02/2010
• Issued: 12/06/2011
• 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.
• Primary Examiner(s): HUSON, MONICA ANNE
• Application Number:
  US12/715,561
• Publication Number:
  US 20100154986A1
• Time in Patent Office: 644 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: B29C 45/56 using mould parts movable during or after injection, e.g. injection-compression moulding B29C45/1705 and B29C45/572 take precedence
• CPC Class Codes: B29K 2711/14 Wood, e.g. woodboard or fibreboard
• 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: B29K 2995/002 Coloured
• CPC Class Codes: B29K 2995/0025 Opaque
• CPC Class Codes: B29K 2995/0026 Transparent
• CPC Class Codes: B29L 2031/3008 Instrument panels
• CPC Class Codes: B29L 2031/3014 Door linings
• CPC Class Codes: B29L 2031/3041 Trim panels
• CPC Class Codes: B32B 2270/00 Resin or rubber layer containing a blend of at least two different polymers
• CPC Class Codes: B32B 2307/4026 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles wall paper B32B2607/02
• CPC Class Codes: B32B 2605/08 Cars
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• 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 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/365 : comprising polycarbonates
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]

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.

Claims

1. A process for manufacturing a multi-layer composite product of injection molded plastic comprising:

(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) positioning a decorative layer on the first mold cover across at least a portion of said first cavity;

(d) 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 core, causing said decorative layer to conform to the shape of said first cavity 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 the stationary mold part to selectively align the first mold core including said decorative composite with the second mold cover, the 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 at least one of said first polymeric material and said second polymeric material comprise a clear plastic; and

(h) solidifying said second polymeric material to form a composite product.

2. The process of claim 1 wherein the other of said first polymeric material and said second polymeric material is a clear plastic.

3. The process of claim 1 wherein said clear plastic comprises any one of polycarbonate, poly(methyl methacrylate), thermoplastic urethane, polyester, copolyester alloy, cyclic olefin copolymer, poly-4-methyl-1-pentene, polysulphone, allyl diglycol carbonate, allyl ester, styrene-acrylonitrile, polystyrene, polyvinyl chloride and blends, alloys and combinations thereof.

4. The process of claim 1 wherein said decorative layer comprises one of a film, a foil, a laminate, a veneer, a fabric or a coating.

5. The process of claim 4 wherein said veneer includes a wood grain pattern.

6. The process of claim 1 wherein one or more of said first or said second polymeric materials includes one or more pigments, tints, colored dyes, metallic flakes or light reflective particles blended therein.

7. The process of claim 1 wherein composite product has a thickness and said thickness is in the range of about 1.0 mm to about 5.0 mm.

8. The process of claim 1 wherein said composite product comprises an appliqué

for decorating or protecting a surface.

9. The process of claim 1 wherein said decorative layer is formed to shape by the injection of said first polymeric material.

10. The process of claim 1 wherein said decorative composite includes molded fastening means for attachment of the composite product to other surfaces.

11. A process for manufacturing a multi-layer composite product of injection molded plastic comprising:

(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) positioning a decorative layer on the first mold cover across at least a portion of said first cavity;

(d) 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, causing said decorative layer to conform to said first mold core and solidifying said first polymeric material to form a decorative composite;

(f) sequentially moving said first mold cover including said decorative composite with respect to the stationary mold part to selectively align the first mold cover including said decorative composite with the second mold core, the 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, wherein at least one of said first polymeric material and said second polymeric material comprise a clear plastic; and

(h) solidifying said second polymeric material to form a composite product.

12. The process of claim 11 wherein the other of said first polymeric material and said second polymeric material is a clear plastic.

13. The process of claim 11 wherein said clear plastic comprises any one of polycarbonate, poly(methyl methacrylate), thermoplastic urethane, polyester, copolyester alloy, cyclic olefin copolymer, poly-4-methyl-1-pentene, polysulphone, allyl diglycol carbonate, allyl ester, styrene-acrylonitrile, polystyrene, polyvinyl chloride and blends, alloys and combinations thereof.

14. The process of claim 11 wherein said decorative layer comprises one of a film, a foil, a laminate, a veneer, a fabric or a coating.

15. The process of claim 14 wherein said veneer includes a wood grain pattern.

16. The process of claim 11 wherein one or more of said first or said second polymeric materials includes one or more pigments, tints, colored dyes, metallic flakes or light reflective particles blended therein.

17. The process of claim 11 wherein composite product has a thickness and said thickness is in the range of about 1.0 mm to about 5.0 mm.

18. The process of claim 11 wherein said composite product comprises an appliqué

for decorating or protecting a surface.

19. The process of claim 11 wherein the decorative layer is formed to shape by the injection of the first polymeric material.

20. The process of claim 11 wherein said backing layer includes molded fastening means for attachment of the composite product to other surfaces.