Patent ID: 7674414

Claim:
A method for manufacturing an appliqué having a decorative layer, 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 lengthened shearing edges which allow for the mold core and mold cover to remain substantially sealed and provide successive layers of injection molded plastic; (b) providing a decorative layer having a front side and a back side; (c) placing said decorative layer across said mold cover overlying at least a portion of said cavity space; (d) aligning said mold core and said mold cover to form a first injection volume therebetween; (e) injecting a first polymer against the backside 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 lengthened shear edges by an amount related to the thickness “a” of an outer layer thereby forming a second injection volume; (h) injecting a second clear polymer into said second injection volume against the front side of said decorative layer to form an outer layer; and (i) solidifying said second polymer to form a molded appliqué, wherein said molded appliqué has a thickness in the range of about 1.0 mm. to about 5.0 mm. and said outer layer, “a”, has a thickness in the range of about 0.5 mm. to about 1.0 mm.