Source: http://www.google.com/patents/US6277312?ie=ISO-8859-1&dq=inassignee:doubleclick
Timestamp: 2014-12-25 23:29:20
Document Index: 732694851

Matched Legal Cases: ['art. 2', 'art. 38', 'art 96', 'art 96', 'art 96', 'art 96', 'art 96', 'art 96']

Patent US6277312 - Printing opaque layer on flat sheet plastic substrate, forming into ... - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsAn in-mold decorating and laser etching method prints a plurality of layers on a flat thin sheet plastic substrate, including combinations of opaque and colored, including translucent and smoked, forms the substrate into a contoured three dimensional workpiece, injection molds the workpiece to an injection...http://www.google.com/patents/US6277312?utm_source=gb-gplus-sharePatent US6277312 - Printing opaque layer on flat sheet plastic substrate, forming into contoured three dimensional workpiece, placing in mold, injecting molten plastic to fuse with workpiece and form molded part, removing, laser etching graphic in opaque layerAdvanced Patent SearchPublication numberUS6277312 B1Publication typeGrantApplication numberUS 09/266,668Publication dateAug 21, 2001Filing dateMar 11, 1999Priority dateMar 11, 1999Fee statusLapsedPublication number09266668, 266668, US 6277312 B1, US 6277312B1, US-B1-6277312, US6277312 B1, US6277312B1InventorsMichael Hansen, Steven M. SchuttOriginal AssigneeSerigraph, Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (28), Non-Patent Citations (2), Referenced by (9), Classifications (18), Legal Events (5) External Links: USPTO, USPTO Assignment, EspacenetPrinting opaque layer on flat sheet plastic substrate, forming into contoured three dimensional workpiece, placing in mold, injecting molten plastic to fuse with workpiece and form molded part, removing, laser etching graphic in opaque layerUS 6277312 B1Abstract An in-mold decorating and laser etching method prints a plurality of layers on a flat thin sheet plastic substrate, including combinations of opaque and colored, including translucent and smoked, forms the substrate into a contoured three dimensional workpiece, injection molds the workpiece to an injection molded part, and laser etches a designated graphic in the opaque layer on the part.
What is claimed is: 1. An in-mold decorating and laser etching method comprising:
providing a flat sheet plastic substrate; printing an opaque layer on said flat substrate; forming said flat substrate into a contoured three dimensional workpiece; placing said workpiece in an injection mold, injecting molten plastic against said workpiece to fuse therewith and form an injection molded part, and removing said part from said injection mold; and laser etching a designated graphic in said opaque layer on said part. 2. The method according to claim 1 wherein said substrate has first and second oppositely facing surfaces, said first surface facing the user, said second surface facing oppositely from said first surface, and comprising:
printing said opaque layer on said first surface; and injecting said molten plastic against said second surface. 3. The method according to claim 2 comprising performing said laser etching step by directing a laser beam at said first surface.
in daytime, said part displays to the user said first color at said graphic; and at nighttime with a backlight, said part displays to the user said second color at said graphic. 15. The method according to claim 14 comprising printing both of said color layers on the same side of said substrate.
printing a first color layer on said substrate; and printing a second color layer on said substrate reflecting ambient daytime light and blocking user view of said graphic, and transmitting light therethrough at nighttime from a backlight and through said first color layer for user viewing of said graphic. 28. The method according to claim 27 wherein said first color layer is printed on said first surface of said substrate, and said second color layer is printed on said first color layer.
printing a first said opaque layer on said first portion of said first surface; printing a second opaque layer on a second portion of said second surface laterally spaced from said first portion; and injecting said molten plastic against said second surface. 31. The method according to claim 30 comprising printing a first color layer on said substrate at one of said first and second portions; and
printing a second color layer on said substrate at the other of said first and second portions. 32. The method according to claim 31 comprising printing a third color layer on said substrate at said other of said first and second portions and in alignment with said first color layer and reflecting daytime ambient light to block user view of said graphic at said other portion and transmitting light from said backlight therethrough at nighttime to provide user view of said graphic through said first color layer at nighttime, and wherein said second color layer reflects ambient daytime light and provides user view of said graphic at said one portion during daytime.
in daytime, said part displays to the user said second color at said graphic; and at nighttime with a backlight, said part displays to the user said first color at said graphic. 35. The method according to claim 34 comprising:
printing said first color on a first portion of said second surface of said flat substrate; printing a third color layer on a second portion of said second surface of said flat substrate; providing a first said blocking surface in said mold engaging said first color layer on said first portion of said second surface at a first said designated window and blocking engagement of said molten plastic against said first window; providing a second blocking surface in said mold engaging said third color layer on said second portion of said second surface at a second designated window and blocking engagement of said molten plastic against said second window; wherein said first surface has a first said graphic opposite said first window, and a second graphic opposite said second window, said part has a first position displaying to the user said first color at said first graphic at nighttime with a backlight, and a second position displaying to the user said third color at said second graphic at nighttime with a backlight. 36. The method according to claim 1 comprising thermal-forming said flat substrate into said contoured three dimensional workpiece.
providing a flat sheet plastic substrate; printing an opaque layer on said flat substrate; forming said flat substrate into a contoured three dimensional substrate; cutting said three dimensional substrate into a plurality of workpieces; placing at least one of said workpieces in an injection mold, closing said mold, injecting molten plastic against said workpiece to fuse therewith and form an injection molded part, and removing said part from said mold; and laser etching a designated graphic in said opaque layer on said part. 38. The method according to claim 37 comprising:
cutting said three dimensional substrate into said plurality of workpieces each having a product portion to be formed into said part, and a registration portion at the periphery of said product portion; placing said workpiece in said mold, and performing a second cutting step further cutting said substrate prior to said injecting step. 39. The method according to claim 38 wherein said second cutting step detaches said registration portion from said product portion.
forming a first set of one or more registration marks in said registration portion during said forming step; and forming a second set of one or more registration marks in said registration portion during said first mentioned cutting step. 46. The method according to claim 45 wherein said first set of registration marks are three dimensional deformations of said substrate at said registration portion, and said second set of registration marks are openings in said substrate at said registration portion.
during said forming step, forming a first set of one or more registration marks in said registration portion; during said first mentioned cutting step, forming a second set of one or more registration marks in said registration portion; and during said mold closing step, performing said second cutting step at least partially detaching said registration portion from said product portion.
BACKGROUND AND SUMMARY The invention relates to in-mold decorating, and more particularly to in-mold decorating with laser etching.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an exploded perspective view of a layering sequence for in-mold decorating and laser etching in accordance with the invention.
FIG. 11 is a sectional view taken along line 11�11 of FIG. 10, and illustrates laser etching.
FIG. 14 is an enlarged view taken along line 14�14 of FIG. 12. FIG. 14 illustrates daytime viewing.
FIG. 36 is a sectional view taken along line 36�36 of FIG. 35.
DETAILED DESCRIPTION OF THE INVENTION FIG. 1 shows a flat thin sheet plastic substrate 50, for example polycarbonate, polyester, etc., extruded in sheet form, and typically 0.005 to 0.030 inch thick. A translucent white layer 52 is printed on substrate 50. Layer 52 is preferably screen printed on substrate 50, though other methods may be used for applying such layer, and other layers, to be described, including offset printing, roll coating, and other methods of applying or coating a layer. Layer 52 is preferably printed with a translucent white catalyzed ink to achieve a high melt temperature and abrasion resistance. Following printing of layer 52, opaque layers 54 and 56 and hard coat layer 58 are printed on the substrate, to provide the layered structure shown in FIGS. 2 and 3. Each of opaque layers 54 and 56 is a black screen printing ink. A single opaque layer may be sufficient, though two layers are preferred, to minimize pinhole leakage, and maximize opacity. Hard coat layer 58 is transparent and preferably has a high abrasion resistance. Layer 52 is printed with laser-vaporization-resistant ink. Layer 54, 56, 58 are printed with laser-vaporization-susceptible inks. In FIGS. 2 and 3, layers 52, 54, 56, 58 are collectively designated by reference character 60.
FIGS. 9 and 10 show the molded part 96 removed from the mold. The molded part includes substrate 50, printed layers 60, and fused and hardened plastic base 98, FIGS. 11 and 13, which had filled mold cavity 70. In the embodiment shown, male mold half 68 includes blocking surfaces 100, 102, FIG. 7, engaging substrate 50 at respective designated windows, 104, 106, FIGS. 10, 13, in alignment with white translucent layer 52 and blocking impingement of molten plastic against substrate 50 at such respective window. Molded part 96 is then etched with laser 108, FIG. 11, at laser beam 109 to provide a designated graphic in the opaque layers on the part, for example �UP� at 110 and �DN� at 112, FIG. 12. Various types of lasers are commercially available for such etching applications, for example one of which is �Insta Mark Laser Marking Systems�, Insignia Icon Stylus, Control Laser Corporation, 7503 Chancellor Drive, Orlando, Fla., USA 32809. As noted above, hard coat layer 58 and opaque layers 56 and 54 are printed with laser-vaporization-susceptible ink, whereby such layers ablate away as etched along the desired graphic by laser 108. White translucent layer 52 is printed with laser-vaporization-resistant ink and hence does not ablate away.
FIG. 14 illustrates the daytime visual display of molded part 96. Incoming ambient light at 114 is reflected by layer 52 back towards the user or viewer at 116. Thus, layer 52 provides a daytime color showing the designated graphics �UP� and �DN� as white lettering against the black background of opaque layers 54, 52 through transparent outer hard coat layer 58.
FIG. 18 illustrates the nighttime visual display in conjunction with the application illustrated in FIGS. 15-17. Molded part 96 is in the form of a toggle or paddle button nested in an automotive instrument cluster panel 118, FIG. 15, and having a central molded stem 120 engaging switch 122 for actuating the latter between a first position, FIG. 16, illuminating light bulb 124, and a second position, FIG. 17, illuminating light bulb 126. Part 96 rocks about integrally molded trinions 128, 130. In the central neutral position shown in FIG. 15, neither light bulb 124 nor 126 is illuminated, and daytime viewing is as shown in FIG. 14, with both �UP� and �DN� being visible by reflection of ambient light as white lettering against a black background. In the nighttime operational mode illustrated in FIG. 16, �UP� on leftward rocking of molded part rocker button 96 as shown at arrow 132, light bulb 124 is illuminated, and light therefrom passes through substrate 50 and white translucent layer 52 as shown at arrow 134, FIG. 18, providing an illuminated white �UP� graphic at 110. Likewise, when rocker button molded part 96 is rocked rightwardly as shown at arrow 136 in FIG. 17, light from illuminated bulb 126 shines through substrate 50 and layer 52, providing an illuminated white �DN� graphic at 112. In each of the rocked positions of FIGS. 16 and 17, the light passing through layer 52 at 134 in addition to the reflective ambient light at 116, FIG. 14, provides additional and brighter indication of the condition of the switch, including during daytime. This provides feedback to the user or driver of whether the switch is in its up or down actuated position. For example, during daytime, in the position of FIG. 16, the graphic �UP� at 110 will be brighter than the graphic �DN� at 112, and hence the user will know the switch is in its activated �UP� condition for the controlled function, e.g. power window activated �UP�. At nighttime, in the position of FIG. 16, the �UP� graphic at 110 will be visible due to the through-transmitted light at 134, and the �DN� graphic at 112 will not be visible, and hence the noted feedback will be provided to the user.
In another embodiment, both light bulbs 124 and 126 are always illuminated at nighttime, e.g. when the driver turns on his parking lights or headlights. In this embodiment, both the �UP� graphic at 110 and the �DN� graphic at 112 are visible to the driver, including at nighttime due to transmitted light 134. The driver may thus select which function is desired, e.g. window �UP� or window down. Other combinations are possible.
FIGS. 31-36 show a further embodiment. FIG. 31 includes substrate 50 having the following layers printed thereon: opaque layer 152; amber layer 154; translucent white layer 156; smoked translucent ink layer 158; opaque layer 160; transparent hardcoat layer 58. Layers 152, 154, 158 are in alignment with window 104. Layers 156, 160 are in alignment with window 106. The molded part is laser etched to provide the graphics shown in FIG. 35 at the resistive heater symbol at 162, and the text graphic �MIRR HEAT� at 164, for example, for a rocker or paddle switch controlling an electrically heated side mirror on an automobile. In daytime, smoked translucent layer 158 reflects ambient light as shown at 166, 168, FIG. 34, and blocks user view of graphics thereunder. The respective half of the rocker button part aligned with window 104 thus appears blank as shown in FIG. 33 at rocker button portion 170, i.e. graphic 162 is not visible. Also in daytime, white translucent layer 156 reflects ambient light as shown at 172, 174, FIG. 34, such that the user sees the etched graphic �MIRR HEAT� at 164 aligned with window 106. This is shown in FIG. 33 at rocker button half 176 where the user sees graphic 164 �MIRR HEAT� during daytime, which graphic is white because layer 156 is the color white. Other colors may be chosen. At nighttime, with illuminated backlights, the resistive heater symbol graphic on rocker button half 170 is visible as shown in FIG. 35 at 162. The graphic color is amber due to the transmitted light as shown at 178 passing through amber layer 154 from the backlight. The other graphic �MIRR HEAT� at 164 at rocker button half 176 is also visible due to light at 180, FIG. 36, passing through white layer 156 from the backlight.
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