IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0013996
(2008-01-14)
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등록번호 |
US-8354050
(2013-01-15)
|
발명자
/ 주소 |
|
출원인 / 주소 |
- High Voltage Graphics, Inc.
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인용정보 |
피인용 횟수 :
5 인용 특허 :
194 |
초록
▼
A method of decorating a molded article is provided that includes the steps of: (a) providing a mold insert comprising a plurality of flock fibers and a permanent adhesive layer;(b) positioning the mold insert in a mold; and(c) introducing resin into the mold, such that a resin contacts the mold ins
A method of decorating a molded article is provided that includes the steps of: (a) providing a mold insert comprising a plurality of flock fibers and a permanent adhesive layer;(b) positioning the mold insert in a mold; and(c) introducing resin into the mold, such that a resin contacts the mold insert to form a molded article. The melting point of the permanent adhesive layer is preferably greater than a temperature of the resin during molding.
대표청구항
▼
1. A method, comprising: providing a mold insert comprising a plurality of flock fibers, a permanent adhesive layer, and a dimensionally stable backing film, wherein the backing film is affixed to the permanent adhesive layer, wherein the permanent adhesive layer is affixed to an opposing second sur
1. A method, comprising: providing a mold insert comprising a plurality of flock fibers, a permanent adhesive layer, and a dimensionally stable backing film, wherein the backing film is affixed to the permanent adhesive layer, wherein the permanent adhesive layer is affixed to an opposing second surface defined by the flock fibers, and wherein the mold insert is non-planar;positioning the mold insert in a mold, wherein the mold insert fits into an extension and/or recess in a mold, thereby preventing dislodgment of the mold insert due to an introduction of a resin; andintroducing the resin into a cavity of the mold, such that a resin contacts the mold insert and the backing film is melt compatible with and forms a melt bond with polymers in the resin to form a molded article, wherein a melting point of the permanent adhesive layer is greater than a temperature of the resin during the introducing step. 2. The method of claim 1, wherein a release sheet is affixed to a first surface defined by the flock fibers. 3. The method of claim 2, wherein neither the permanent adhesive nor the backing film is a fabric to permit the mold insert to be formed into a three-dimensional shape. 4. The method of claim 1, wherein the permanent adhesive is a thermoset adhesive selected from the group consisting of polyethylene, polyurethane, polyamide, phenolic, alkyd, amino resin, polyester, epoxide, silicone, and mixtures thereof, wherein the mold insert is free of a hot melt adhesive, and wherein the plurality of flock fibers are free of acrylic. 5. The method of claim 4, wherein the permanent adhesive is fully activated before positioning of the mold insert in the mold. 6. The method of claim 1, wherein the permanent adhesive is a thermoplastic adhesive selected from the group consisting of polyethylene, polyurethane, polyamide, phenolic, alkyd, amino resin, polyester, epoxide, silicone, and mixtures thereof and wherein the plurality of flock fibers are free of acrylic. 7. The method of claim 1, wherein the permanent adhesive layer is a cast, continuous film selected from the group consisting of polyethylene, polyurethane, polyamide, phenolic, alkyd, amino resin, polyester, epoxide, silicone, and mixtures thereof and wherein the plurality of flock fibers are free of acrylic. 8. The method of claim 1, wherein the permanent adhesive layer is an extruded, continuous film selected from the group consisting of polyethylene, polyurethane, polyamide, phenolic, alkyd, amino resin, polyester, epoxide, silicone, and mixtures thereof and wherein the plurality of flock fibers are free of acrylic. 9. The method of claim 1, wherein melting and softening points of the flock are no less than and a melting point of the permanent adhesive layer is greater than a maximum resin temperature in the mold. 10. The method of claim 1, wherein the mold insert is formed by direct flocking techniques. 11. The method of claim 1, wherein the mold insert is a transfer comprising a release sheet adhered by a release adhesive to a first surface of the flock fibers and wherein the permanent adhesive is adhered to a second surface of the flock fibers, the first and second surfaces being in an opposed relationship. 12. The method of claim 2, wherein the permanent adhesive layer is positioned between the flock fibers and the backing film. 13. The method of claim 12, wherein the plurality of flock fibers are oriented at least substantially perpendicular to an adjacent surface of the permanent adhesive layer. 14. The method of claim 12, wherein the backing film is a cast or extruded continuous film and further comprising before the positioning step: contacting the plurality of flock fibers and permanent adhesive to the backing film to form a substantially planar assembly; andthereafter forming, by thermoforming, reforming, vacuum forming, and/or hydro-forming the assembly into the mold insert into a three dimensional, non-planar shape. 15. The method of claim 12, wherein the backing film has a softening and/or melting point that is above the maximum temperature experienced by the backing film during the introducing step. 16. The method of claim 12, wherein the backing film is not a fabric and wherein the backing film is selected from the group consisting essentially of polystyrene, an acrylic polymer, polyvinyl, polyolefin, cellulose, polycarbonate, ABS, polypropylene, polyester, polyethylene, and mixtures and composites thereof. 17. The method of claim 12, wherein the backing film is a cast, continuous film and wherein the backing film is selected from the group consisting essentially of polystyrene, an acrylic polymer, polyvinyl, polyolefin, cellulose, polycarbonate, ABS, polypropylene, polyester, polyethylene, and mixtures and composites thereof. 18. The method of claim 12, wherein the backing film is an extruded, continuous film and wherein the backing film is selected from the group consisting essentially of polystyrene, an acrylic polymer, polyvinyl, polyolefin, cellulose, polycarbonate, ABS, polypropylene, polyester, polyethylene, and mixtures and composites thereof. 19. The method of claim 1, wherein the permanent adhesive is fully activated before the positioning step. 20. The method of claim 12, wherein the mold insert further comprises a second adhesive located between the permanent adhesive layer and the backing film. 21. The method of claim 12, wherein the mold insert further comprises a barrier film positioned between the flock fibers and the backing film and wherein the barrier film includes a thermally insulative material. 22. The method of claim 1, wherein the mold insert comprises a foam backing material or precursor thereof. 23. The method of claim 1, wherein the plurality of flock fibers comprise flock fibers of different colors and the color is permanently imparted to the fibers by at least one of pigment-in-polymer and dying techniques. 24. The method of claim 2, wherein the providing step comprises: establishing a vacuum connection with the release sheet using one or more vacuum suction cups; andtransporting a mold insert film and placing the mold insert film in a forming tool by means of the vacuum connection to form the mold insert. 25. A method, comprising: providing a non-planar, dimensionally stable three dimensional mold insert formed from a mold insert film comprising a flock layer, a backing film, and a layer of permanent adhesive bonding the flock layer to the backing film, wherein the flock layer comprises flock fibers substantially perpendicular to a surface of the backing film;inserting the mold insert into a cavity of a mold, wherein a non-planar surface of the mold insert matches substantially a non-planar surface of the mold, thereby preventing dislodgment of the mold insert due to an introduction of a flowable resin;introducing the flowable resin into the cavity of the mold to form a molded article comprising the mold insert and the resin, the backing film being melt compatible with and forming a melt bond with polymers in the resin; andafter the resin solidifies, ejecting the molded article from the mold. 26. The method of claim 25, wherein the mold insert comprises a carrier sheet attached to a first side of the flock layer while the backing film is bonded to an opposing second end of the flock layer and wherein the mold insert is free of a hot melt adhesive. 27. The method of claim 25, wherein the permanent adhesive is activatable, wherein the flock layer is free of acrylic, and wherein the providing step comprises: applying a release adhesive in a desired pattern to a dimensionally stable carrier sheet;applying a decorative medium to the release adhesive;applying the layer of activatable adhesive to the exposed ends of the decorative medium;contacting the backing film with the layer of activatable adhesive;heating the layer of activatable adhesive to fully activate the layer of activatable adhesive and form an assembly; andforming, by thermoforming, reforming, vacuum forming, and/or hydro-forming the assembly into the mold insert into a three dimensional, non-planar shape. 28. The method of claim 25, wherein the mold insert comprises a thermally insulating barrier film and a second layer of adhesive bonding the barrier film to the flock layer. 29. The method of claim 25, wherein the permanent adhesive is activatable and wherein the providing step comprises: applying in a desired pattern the layer of activatable adhesive to the backing film; andapplying flock to the layer of activatable adhesive. 30. The method of claim 25, wherein the backing film is a high polymeric substance and not a fabric. 31. The method of claim 30, wherein the permanent adhesive is activatable, wherein the polymeric substance is a polycarbonate, and wherein the activatable adhesive is fully activated before the inserting step. 32. The method of claim 30, wherein the resin and backing film are plastics and wherein melting and softening points of the flock are no less than and a melting point of the permanent adhesive layer is greater than a maximum resin temperature in the mold. 33. The method of claim 30, wherein the resin and backing film have differing chemical compositions and wherein melting and softening points of the flock are no less than and a melting point of the permanent adhesive layer is greater than a maximum resin temperature in the mold. 34. The method of claim 25, wherein the resin is a polycarbonate and wherein melting and softening points of the flock are no less than and a melting point of the permanent adhesive layer is greater than a maximum resin temperature in the mold. 35. The method of claim 25, wherein the permanent adhesive is activatable, wherein the layer of activatable adhesive comprises an activatable permanent adhesive film and wherein the three dimensional mold insert is formed, before the inserting step, by steps comprising: laminating the flocked transfer sheet, the activatable permanent adhesive film, and the backing film together to form the mold insert; andthereafter forming the mold insert into a three dimensional shape matching at least a portion of a mold. 36. The method of claim 35, further comprising: locating the mold insert in the mold; andintroducing the flowable resin into the mold, such that the flowable resin contacts the mold insert to form the molded article. 37. The method of claim 35, wherein a release sheet is affixed to a first surface of the flock layer and the activatable permanent adhesive film to an opposing second surface defined by the flock layer. 38. The method of claim 37, wherein, during the laminating step, the activatable permanent adhesive is fully activated. 39. The method of claim 35, wherein the activatable permanent adhesive is a thermoset adhesive selected from the group consisting of polyethylene, polyurethane, polyamide, phenolic, alkyd, amino resin, polyester, epoxide, silicone, and mixtures thereof and wherein the plurality of flock fibers are free of acrylic. 40. The method of claim 35, wherein a continuous length of the flocked transfer sheet comprises a plurality of discrete flocked regions. 41. The method of claim 35, wherein the activatable permanent adhesive film is a cast, continuous film and is selected from the group consisting of polyethylene, polyurethane, polyamide, phenolic, alkyd, amino resin, polyester, epoxide, silicone, and mixtures thereof and wherein the plurality of flock fibers are free of acrylic. 42. The method of claim 35, wherein the activatable permanent adhesive film is an extruded, continuous film and is selected from the group consisting of polyethylene, polyurethane, polyamide, phenolic, alkyd, amino resin, polyester, epoxide, silicone, and mixtures thereof and wherein the plurality of flock fibers are free of acrylic. 43. The method of claim 35, wherein the activatable permanent adhesive film is not a fabric. 44. The method of claim 35, wherein, after the laminating step, a plurality of mold inserts are located on a continuous length of the backing film and further comprising: cutting the backing film to provide a plurality of disconnected mold inserts. 45. The method of claim 44, wherein, after the cutting step, the mold insert comprises a flocked area surrounded at least substantially by an unflocked area of the backing film. 46. A method, comprising: providing a mold insert comprising a plurality of flock fibers, a permanent adhesive layer, and a dimensionally stable backing film, wherein the backing film is affixed to the permanent adhesive layer, wherein the permanent adhesive layer is affixed to an opposing second surface defined by the flock fibers, wherein the mold insert is non-planar, wherein the flock fibers are free of acrylic, and wherein the permanent adhesive is selected from the group consisting of polyethylene, polyurethane, polyamide, phenolic, alkyd, amino resin, polyester, epoxide, silicone, and mixtures thereof;positioning the mold insert in a mold, wherein the mold insert fits into an extension and/or recess in the mold, thereby preventing dislodgment of the mold insert due to an introduction of a resin; andintroducing the resin into the mold, such that a resin contacts the mold insert and the backing film is melt compatible with and forms a melt bond with polymers in the resin to form a molded article. 47. The method of claim 46, wherein the mold insert is free of a hot melt adhesive and the permanent adhesive is fully cross-linked before the positioning step. 48. A method, comprising: providing a mold insert comprising a plurality of flock fibers, a fully activated permanent adhesive layer, and a dimensionally stable backing film, wherein the backing film is affixed to the permanent adhesive layer, wherein the permanent adhesive layer is affixed to an opposing second surface defined by the flock fibers, and wherein the mold insert is non-planar;positioning the mold insert in a mold, wherein the mold insert fits into an extension and/or recess in the mold, thereby preventing dislodgment of the mold insert due to an introduction of a resin; andintroducing the resin into the mold, such that a resin contacts the mold insert and the backing film is melt compatible with and forms a melt bond with polymers in the resin to form a molded article, wherein a melting point of the permanent adhesive layer is greater than a temperature of the resin during the introducing step. 49. The method of claim 48, wherein the flock fibers are free of acrylic and wherein the permanent adhesive is selected from the group consisting of polyethylene, polyurethane, polyamide, phenolic, alkyd, amino resin, polyester, epoxide, silicone, and mixtures thereof. 50. A method, comprising: providing a mold insert comprising a plurality of flock fibers, a permanent adhesive layer, and a dimensionally stable backing film, wherein the backing film is affixed to the permanent adhesive layer, wherein the permanent adhesive layer is affixed to an opposing second surface defined by the flock fibers, and wherein, the mold insert is non-planar;positioning the mold insert in a mold, wherein the mold insert fits into an extension and/or recess in the mold, thereby preventing dislodgment of the mold insert due to an introduction of a resin; andintroducing the resin into the mold, such that a resin contacts the mold insert and the backing film is melt compatible with and forms a melt bond with polymers in the resin to form a molded article, wherein melting and softening points of the flock are no less than and a melting point of the permanent adhesive layer is greater than a maximum resin temperature in the mold during the introducing step. 51. The method of claim 48, wherein the permanent adhesive is fully activated, wherein the flock fibers are free of acrylic, and wherein the permanent adhesive is selected from the group consisting of polyethylene, polyurethane, polyamide, phenolic, alkyd, amino resin, polyester, epoxide, silicone, and mixtures thereof.
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