Patent Publication Number: US-2009239040-A1

Title: Method for manufacturing molded article

Description:
BACKGROUND OF THE INVENTION  
     1. Field of the Invention 
     The present invention relates to manufacturing methods, particularly to a method for manufacturing a molded article. 
     2. Description of Related Art 
     Molded articles, such as molded shells, are widely used in many technological fields. One example is a molded shell used with a portable electronic device (e.g., a mobile phone) for containing internal electronic components. Another example is a molded shell used with a piece of furniture (e.g., a mini sofa) to provide decoration. 
     Typically, In-Mold Lamination (IML) technology is used to manufacture a molded shell with a leather appearance. During process of manufacturing, a piece of leather is placed in a mold for in-mold laminating to achieve the molded shell with the leather appearance. However, at least because leather has low resistance to high temperatures, the piece of leather can be damaged during manufacturing. Thereby, quality is decreased. In addition, during the molding process, the leather pieces tend to be damaged (e.g., scraped) by improper/imprecise mold design. Therefore, again, quality is decreased. 
     Therefore, a need exists in the art to address these deficiencies and inadequacies. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Many aspects of the present molded article manufactured by the present method can be better understood with reference to the following drawing. This drawing is not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present molded article. Moreover, in the drawing like reference numerals designate corresponding parts throughout the view. Wherever possible, the same reference numbers are used throughout the drawing to refer to the same or like elements of an embodiment. 
         FIG. 1  is a top plan view of a molded article manufactured by a method according to an exemplary embodiment. 
         FIG. 2  is a cross-sectional view of the molded article of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS 
     Referring to  FIGS. 1 and 2 , the molded shell  10  includes a substrate  11 , having a textured surface  12 , and a leather coating layer  13 . The leather coating layer  13  covers the textured surface  12 . 
     The substrate  11  can be formed by injection molding materials, such as plastics, rubbers, or silicons. The plastics can be one or more plastics selected from a group consisting of PVC (i.e., polyvinyl chloride), ABS (i.e., acrylonitrile-butadiene-styrene), PC (i.e., polycarbonate), polystyrene, polypropylene, and polyurethane. 
     A conventional injection mold (not shown) is provided for manufacturing the molded shell  10  and typically includes a core insert and a mold cavity. The core insert has a textured surface corresponding to the textured surface  12  on the substrate  11 . The textured surface can be attained by chemical etching or discharging etching. 
     During manufacturing, the core insert mates with the mold cavity to mold the substrate  11  therein. The textured surface  12  is formed on an exterior surface of the substrate  11 . The textured surface  12  has substantially the same shape and size as that of the textured surface of the core insert. Finally, the leather coating layer  13  is formed/coated on the textured surface  12  by a conventional coating method. 
     It is to be understood, however, that even through numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.