Patent ID: 7351368
Filing Date: 2008-04-01
Classification: B29C,B29K,B32B,B44C,Y10S,Y10T

Abstract:
1. A method, comprising: providing a flocked transfer sheet, a pre-formed, self-supporting, and thermosetting adhesive film, and a thermoplastic backing film; thereafter laminating the flocked transfer sheet, the thermosetting adhesive film, and the backing film together to form a mold insert; and forming the mold insert into a three-dimensional shape that substantially corresponds to a surface of at least a portion of a mold; positioning the formed mold insert in the mold; while the formed mold insert is positioned in the mold, introducing a resin into the mold to form a molded article comprising resin and the formed mold insert, wherein the thermosetting adhesive film is thermoset before the introducing step, wherein the formed mold insert retains the three-dimensional shape after the forming step and before positioning in the mold, and wherein a first orientation of the flock fibers before the introducing step is substantially the same as a second orientation of the flock fibers after the introducing step.