Patent ID: 6221304
Filing Date: 2001-04-24
Classification: B29C,B29L

Abstract:
A method of manufacturing a film coated article comprising the steps of:providing a pre-molded thin flexible film having a decorative surface and a backing surface, said pre-molded thin flexible film having a three-dimensional shape;moving a loading station to a first position accessible to an operator;after said moving step, placing said pre-molded three-dimensional thin flexible film into said loading station and smoothing said pre-molded three-dimensional thin flexible film so that there are no wrinkles in said pre-molded three-dimensional thin flexible film, said decorative surface juxtaposed and mating with said loading station, said loading station retaining said pre-molded three-dimensional thin flexible film in an unwrinkled state;after said placing step, moving said loading station from said first position to a second position, said second position being located above said first position and freeing said first position to receive said article;after moving said loading station, transferring said pre-molded three-dimensional thin flexible film from said loading station to a robotically controlled loader, said loader juxtaposed and mating with said backing surface, said loader retaining said pre-molded three-dimensional thin flexible film in an unwrinkled state;after transferring said pre-molded three-dimensional thin flexible film to said loader, positioning said loader and said pre-molded three-dimensional thin flexible film between an open mold press, said press having a cavity and a core;after said positioning step, transferring said pre-molded three-dimensional thin flexible film from said loader to said cavity, said decorative surface juxtaposed and mating with said cavity, said cavity retaining said Pre-molded three-dimensional thin flexible film in an unwrinkled state;closing said press and injecting a polymer material against said backing surface to produce the film coated article having a rigid substrate of the injected polymer material fused to said backing and displaying said decorative surface;opening said mold and transferring said article to an unloader, said decorative surface juxtaposed said unloader;transferring said molded article to an unloading station positioned near said first position while said loading station is in said second position; andreleasing said molded article from said unloader at said unloading station.