Patent ID: 8083979
Filing Date: 2011-12-27
Classification: B29C,B29L,B32B,B60R,Y10T

Abstract:
1. A method for manufacturing an appliqué or trim panel having a decorative layer including a digitally printed image, a backing layer and an outer layer, comprising the steps of: (a) providing a mold core and a mold cover which cooperate to form a cavity space wherein said core and cover are aligned along one or more shearing edges; (b) providing a decorative layer, said decorative layer having a front side and a back side and including an image digitally printed on said front side; (c) placing said decorative layer in said cavity space; (d) aligning said mold core and said mold cover to form a first injection volume; (e) injecting a first polymer against the back side of said decorative layer to substantially conform said decorative layer against the cover side of said first injection volume thereby forming a decorative composite comprising a backing layer at least partially formed behind said decorative layer; (f) solidifying said backing layer; (g) retracting said core and said decorative composite from said mold cover along said one or more shear edges by an amount related to the thickness of said outer layer thereby forming a second injection volume; (h) injecting a second polymer into said second injection volume against the front side of said decorative composite to form an outer layer; and (i) solidifying said second polymer to form said molded appliqué or trim panel, wherein said second polymer is a clear plastic and wherein said decorative layer includes a metal foil, film, fabric, veneer, coating, laminate or paper substrate which is less than about 0.020 inches in thickness and has the front side decorated by a digital image from an inkjet printer.