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Molded parts with mixed material surface areas and processes for their production

A surface area, product technology, applied in the direction of household appliances, other household appliances, coatings, etc., can solve the problem of thin shell parts that do not allow the use of concealment and protection

Inactive Publication Date: 2008-02-20
DOW GLOBAL TECH LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0004] But thin and small electronic communication and data devices must use very thin molded plastic parts, which precludes the application of this method, because thin housing parts do not allow the use of relatively deep trenches to hide and protect the seams of adjacent materials groove

Method used

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  • Molded parts with mixed material surface areas and processes for their production
  • Molded parts with mixed material surface areas and processes for their production
  • Molded parts with mixed material surface areas and processes for their production

Examples

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Embodiment

[0058] In an embodiment of the products and methods of the present invention (Experiment 1), a molded polycarbonate substrate was provided with a combination of metal and suede surface areas, wherein the metal was the first material and was secured in strips throughout the suede. on the surface area of ​​the upper leather. The metal in this example is anodized aluminum. The metal has a thickness of 0.006 inches (0.15 millimeters) and is laminated with a thermoplastic bonded bilayer film ("2-ply") with polyethylene (PE) on one side and polyamide (PA) on the other . This adhesive film has 10 grams (gm) PE / square meter ( / m 2 ) and 40 g PA / m 2 , with a total density of 0.96 grams / cubic centimeter (gm / cm 3 ), with a melting point ranging from 120 to 125°C. The film was laminated to the metal using a flatbed laminator set at 135°C and 80 pounds per square inch (psi) (0.55 MPa) lamination pressure with the PE side facing the metal. The metal is cut into desired surface area sha...

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Abstract

The present invention provides thin injection molded plastic articles with an attractive, surface area of at least two different materials, such as leather, fabric, wood, metal or other semi-rigid surface material. These molded articles have desired combinations of thin dimensions, aesthetics and / or durability with the true feel of the real materials. The molded plastic articles thus have a plastic substrate component with a front decorative surface having at least two decorative surface areas of layers of different first (1) and second (2) materials having adjacent and connecting surface areas that are generally coplanar or continuous, including at the border line where the two surface layer materials meet. Relative to the front surface, at least a portion of the first material is located on top of and overlaps at least a portion of the second. In the process embodiment two surface material pieces are located in a mold cavity, the two materials together being located so as to each provide a surface area on the front side of the molded part. Optionally there is an adhesive and / or backing material (3, 5) on the back or non-decorative side of one or both surface material pieces. A molding plastic (9) is injected into the mold (6, 7) that contacts and adheres to the back side of the surface material (s) and provides a molded on plastic substrate component. While the molding plastic is sufficiently fluid, pressure is applied to the cavity, preferably in an injection molding process, sufficient to compress and / or form the two different surface materials into a substantially coplanar or continuous surface and press the thicker overlapped area to a necessary depth into the plastic substrate component.

Description

[0001] The present invention relates to molded plastic parts having a plastic substrate with one surface layer comprising a flexible or semi-rigid surface material (such as fabric, leather, foil, wood veneer or similar semi-rigid surface material) which may be selected from a variety of Different and immediately adjacent surface areas of at least two different surface materials. The present invention also relates to an efficient method of manufacturing these parts in which the surface material conforms and adheres uniformly to the plastic substrate with a very smooth and aesthetically pleasing boundary line or transition between the two materials. The resulting parts have good appearance, precise dimensions, thin part cross-sections and strong material edges. Background of the invention [0002] In the field of molded plastic parts there are many methods of providing surface layers or surface inserts of different materials fabric, leather, metal, wood or paper on the surface o...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B29C45/14
CPCB29C45/14778B29C2045/14901B29K2711/08B29K2711/14B29K2705/00B29L2031/3041B29C45/14508B29C45/1418
Inventor V·瓦尼R·阿布格哈内姆E·L·马奇班克斯M·E·胡斯C·E·彼德松T·E·范科内特M·M·霍格兰J·A·兰梅德
Owner DOW GLOBAL TECH LLC
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