Faux-stitched plastic articles and methods of forming same
By integrating faux stitching with stress-whitened areas into plastic articles through a thermoformed appliqué and injection molded platform, the challenges of cost and visibility of fake stitches are addressed, providing a realistic and cost-effective solution.
Patent Information
- Application Number
- JP2025524174
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-01-11
- Filing Date
- 2024-01-11
- Publication Date
- 2026-01-27
AI Technical Summary
Existing plastic articles with fake stitches are either cost-prohibitive or easily identifiable as not being real, and there is a need for a more realistic and cost-effective solution.
Integrate faux stitching into a plastic article during its formation by using a thermoformed plastic sheet appliqué with stress-whitened areas that mimic real stitching, combined with an injection molded plastic platform, creating a distinct color contrast.
Achieves a realistic and cost-effective faux stitching effect that mimics real stitching with a different color, enhancing the aesthetic appeal of plastic articles.
Smart Images
Figure 2026502770000001_ABST
Abstract
Description
[Technical Field]
[0001] CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 479,445, filed January 11, 2023, the entire contents of which are incorporated herein by reference.
[0002] Field
[0002] The present disclosure relates to plastic articles with faux stitching, and more particularly to automotive interior trim articles with faux stitching, such as floor mats. [Background technology]
[0003] background
[0003] Stitches formed from thread may be provided on plastic articles, but such are often cost-prohibitive.
[0004]
[0004] Fake stitches may be formed on plastic articles, but such are known to be the same color as the article, making them easily identifiable as not being real stitches, i.e. stitches formed with thread.
[0005]
[0005] The present disclosure provides plastic articles with faux stitching that looks like real stitching, particularly with stitching that has a different color than the color of the article. Summary of the Invention [Means for solving the problem]
[0006] overview
[0006] The present disclosure provides a faux stitch that is integrated into a plastic article during the formation of the article.
[0007]
[0007] In at least one embodiment, there is provided a plastic article having faux stitching, the plastic article having a front side and a back side opposite the front side, comprising an applique formed from a thermoformed plastic sheet, and an injection molded plastic platform, wherein the applique is insert molded into the platform with the back side of the applique joined to the platform, at least one faux stitch line formed on the front side of the applique, the at least one faux stitch line comprising a plurality of faux stitches, each faux stitch of the plurality of faux stitches comprising a stress whitened area of the applique.
[0008] In at least one embodiment, the front side of the appliqué further includes a plurality of standing pleats.
[0009]
[0009] In at least one embodiment, at least one faux stitch line at least partially surrounds at least one standing pleat of the plurality of standing pleats.
[0010]
[0010] In at least one embodiment, at least one faux stitch line is disposed between adjacent standing pleats of the plurality of standing pleats.
[0011]
[0011] In at least one embodiment, at least one fake stitch line is disposed on at least one stitch path, the at least one stitch path being disposed between adjacent standing pleats of the plurality of standing pleats, and the at least one stitch path forming a boundary with the adjacent standing pleat.
[0012]
[0012] In at least one embodiment, the at least one faux stitch line comprises a plurality of faux stitch lines, each of the plurality of faux stitch lines comprising a respective plurality of faux stitches, each faux stitch of the respective plurality of faux stitches comprising a respective stress whitened area of the appliqué, and the plurality of faux stitch lines completely surround the plurality of standing pleats.
[0013] In at least one embodiment, each of the plurality of standing pleats has a matching polygonal shape.
[0014] In at least one embodiment, the polygonal shape is a quadrilateral shape.
[0015]
[0015] In at least one embodiment, the plurality of fake stitch lines are arranged on a plurality of respective stitch paths, the plurality of respective stitch paths being arranged between respective adjacent standing pleats of the plurality of standing pleats, and the plurality of respective stitch paths being completely bordered by the respective adjacent standing pleats.
[0016] In at least one embodiment, the injection molded plastic platform is formed from an elastomer and / or the injection molded plastic platform has a thickness in the range of 1.5 mm to 3.5 mm.
[0017] In at least one embodiment, the thermoformed plastic sheet is formed from a thermoplastic plastic and / or the thermoformed plastic sheet has a thickness in the range of 0.1 mm to 1.5 mm.
[0018]
[0018] In at least one embodiment, the article has an exterior surface having an area provided by a front side of a plastic applique and an area provided by a front side of an injection-molded plastic platform adjacent to the front side of the plastic applique.
[0019]
[0019] In at least one embodiment, the fake stitches each comprising each stress-whitened area of the appliqué each have a longitudinal length in the range of 1 mm to 4 mm and / or a width perpendicular to the longitudinal length in the range of 0.1 mm to 0.9 mm.
[0020] In at least one embodiment, the faux stitches that each comprise a stress-whitened area of the appliqué have a different color than the border area of the appliqué that borders the faux stitch.
[0021] In at least one embodiment, the plastic article is an automotive interior trim article.
[0022] In at least one embodiment, the plastic article is a floor mat and / or a floor tray.
[0023]
[0023] In at least one embodiment, a method is provided for forming a plastic article having faux stitching, the method including: inserting an applique having a front side and a back side opposite the front side into a molding cavity of an injection molding mold, the applique being formed from a thermoformed plastic sheet; injecting plastic into the molding cavity to form an injection molded plastic platform, the back side of the applique being joined to the platform; and forming at least one faux stitch line on the front side of the applique, the at least one faux stitch line comprising a faux stitch, each faux stitch comprising a stress-whitened area of the applique formed during injection of plastic into the molding cavity.
[0024]
[0024] In at least one embodiment, the front side of the applique further includes a plurality of standing pleats before being inserted into the molding cavity of the injection mold, and at least one fake stitch line at least partially surrounds at least one of the plurality of standing pleats.
[0025]
[0025] In at least one embodiment, the method further includes forming a plurality of faux stitch lines on the front side of the appliqué, each of the plurality of faux stitch lines comprising a faux stitch, each of the faux stitches comprising a stress-whitened area of the appliqué formed during injection of plastic into the mold cavity, and the plurality of faux stitch lines completely surrounding the plurality of standing pleats.
[0026]
[0026] In at least one embodiment, the method further includes an article having an outer surface having an area provided by a front side of the plastic applique and an area provided by a front side of an injection-molded plastic platform adjacent to the front side of the plastic applique.
[0027] BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The above and other features of the present disclosure, as well as the methods for achieving them, will become more apparent and better understood by referring to the following description of the embodiments described in this specification in conjunction with the accompanying drawings. [Brief explanation of the drawings]
[0028] [Figure 1]
[0028] FIG. 1 is a front plan view of an article of the present disclosure. [Figure 2]
[0029] FIG. 2 is an enlarged view of the appliqué section of the plan view of the article of FIG. 1. [Figure 3]
[0030] FIG. 3 is an enlarged view of the pleats of the appliqué section of FIG. 2. [Figure 4]
[0031] FIG. 2 is a plan view of a mold for forming the article of FIG. 1. [Figure 5]
[0032] FIG. 5 is an enlarged view of a section of the molding surface of the mold of FIG. 4. [Figure 6]
[0033] FIG. 2 is a plan view of the appliqué prior to forming the article. [Figure 7]
[0034] FIG. 7 is an enlarged view of an applique section of the applique of FIG. 6. [Figure 8]
[0035] 5 is a plan view of the mold of FIG. 4 onto which the appliqué is disposed. DETAILED DESCRIPTION OF THE INVENTION
[0029] Detailed Description
[0036] It will be appreciated that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention herein is capable of other embodiments and of being practiced or carried out in various ways. Also, it will be appreciated that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting, as may be understood by one of ordinary skill in the art.
[0030]
[0037] 1 illustrates a plastic article 100, particularly as an interior trim article for a motor vehicle 10, and more particularly as a floor article such as a floor mat / tray that may be disposed on a floor covering 12 of the motor vehicle 10. As shown, the floor covering 12 may include carpeting disposed within the passenger area or cargo area.
[0031]
[0038] As shown, the plastic article 100 comprises a plastic molding platform 120 (e.g., injection molded) having a flat, horizontal bottom wall 122 (which may be referred to as a base wall or floor) that is at least partially surrounded by a vertically upstanding peripheral rim 124 (which may be referred to as a vertically upstanding containment wall). As shown, the peripheral rim 124 extends continuously around the bottom wall 122. It should be understood that the peripheral rim 124 is preferably continuous / uninterrupted around the bottom wall 122 in that the bottom wall 122 is completely surrounded / encircled by the peripheral rim 124 on all bounding sides (i.e., 360 degrees). In other embodiments, the peripheral rim 124 may be discontinuous / intermittent around the bottom wall 122. For example, the peripheral rim 124 may be discontinuous / intermittent around the bottom wall 122 on one or more sides of the bottom wall 122, or may be completely removed on one or more sides of the bottom wall 122. It should also be understood that while bottom wall 122 is considered to be horizontal and peripheral rim 124 is considered to be vertical, and relates to flooring or other items that are horizontally oriented, bottom wall 122 may not be so oriented for other applications.
[0032]
[0039] As shown, separately formed plastic appliqué 146 is attached by insert molding to platform 120, particularly during injection molding of platform 120. Insert injection molding may be understood as a process in which a component is inserted into mold 200 ( FIG. 4 ) prior to the introduction of heated / molten plastic during injection. As shown, exterior (front) surface 102 of article 100 comprises platform exterior (front) surface region 104 and appliqué exterior (front) surface region 106 provided by front side 148 of appliqué 146. In appliqué region 106 of front surface 102 of article 100, platform 120, particularly bottom wall 122, is below appliqué 146. More specifically, the front side 126 of the platform 120, and in particular the bottom wall 122, faces the rear side 156 (FIG. 8) (opposite the front side 148) of the appliqué 146, with both sides 126, 156 heat-bonded (in-mold welded) together without the need for a separate adhesive.
[0033]
[0040] As best shown by Figure 2, a section 150 of the appliqué exterior (front) surface region 106 of the front surface 102 of the article 100 of Figure 1 is shown, provided by the front side 148 of the appliqué 146, having a plurality of adjacent, congruent polygonal (quadrilateral) shaped erected pleats 152. More specifically, the erected pleats 152 are shown having a diamond shape formed by a parallelogram, or more specifically, a rhombus, in which two angles α1 between intersecting angled sides S1, S4 and S2, S3 are less than 90 degrees, and two other angles α2 between intersecting angled sides S1, S3 and S2, S4 are greater than 90 degrees. More specifically, angle α1 may be in the range of 60 degrees to 85 degrees, and angle α2 may be in the range of 95 degrees to 120 degrees.
[0034]
[0041] As shown, in the non-appliqué (front) surface region 106 of the front surface 102 of the article 100 (again, provided by the front side 148 of the appliqué 146), the periphery / perimeter of each pleat 152 is at least partially, and more particularly, completely, surrounded by four elongated, adjacent linear faux stitch lines L1, L2, L3, and L4 disposed between adjacent pleats 152 and recessed relative to the front surface 154 of the pleat 152. The pair of stitch lines L1, L2 are generally parallel to each other (e.g., within 5 degrees, including parallel), while the pair of stitch lines L3, L4 are generally parallel to each other (e.g., within 5 degrees, including parallel). The pair of stitch lines L1, L2 and the pair of stitch lines L3, L4 are perpendicular to each other. The stitch lines L1-L4 are generally parallel to the corresponding side surfaces S1-S4 of the pleat 152 (e.g., within 5 degrees, including parallel).
[0035]
[0042] Stitch lines L1, L2, L3, and L4 are disposed between adjacent pleats 146 and are disposed on corresponding elongated linear stitch paths P1, P2, P3, and P4 that are recessed relative to the front surface 154 of the pleat 152. As shown, the perimeter / perimeter of each pleat 152 is bounded and defined by stitch paths P1-P4. As shown, the pair of stitch paths P1, P2 are generally parallel to each other (e.g., within 5 degrees, including parallelism), while the pair of stitch paths P3, P4 are generally parallel to each other (e.g., within 5 degrees, including parallelism). The pair of stitch paths P1, P2 and the pair of stitch paths P3, P4 are perpendicular to each other. The stitch paths P1-P4 are generally parallel to the corresponding side surfaces S1-S4 of the pleat 152 (e.g., within 5 degrees, including parallelism).
[0036]
[0043] As shown, the stitch line L1 / stitch path P1 are generally parallel to one another (e.g., within 5 degrees of parallelism). Similarly, the stitch line L2 / stitch path P2, the stitch line L3 / stitch path P3, and the stitch line L4 / stitch path P4 are generally parallel to one another (e.g., within 5 degrees of parallelism).
[0037]
[0044] As best shown in Figure 3, stitch lines L1-L4 comprise a plurality of stitches 160 arranged end-to-end. Each stitch 160 may have a longitudinal stitch length 162 ranging from 1 mm to 4 mm, a stitch width 164 (perpendicular to the longitudinal length) ranging from 0.1 mm to 0.9 mm, and a longitudinal stitch (spacing) gap 166 ranging from 0.25 mm to 1 mm. Stitch paths P1-P4 may have a width 168 ranging from 0.75 mm to 2.25 mm.
[0038]
[0045] As described in more detail below, the plastic molding platform 120 may be formed, inter alia, using injection molding from a polymer composition, such as a thermoplastic polymer composition, with a wall thickness ranging from 1.5 mm to 3.5 mm, more particularly 2.0 mm to 3.0 mm. In certain applications (e.g., floor mats), the polymer composition may be an elastomeric polymer composition, such as a thermoplastic elastomeric polymer composition.
[0039]
[0046] The elastomeric polymer composition may be a polymer composition having a glass transition temperature (Tg) of less than 23°C and being at most 50% crystalline (i.e., the composition contains 50% or more amorphous phase, up to 100% amorphous phase). Additionally or alternatively, the elastomeric polymer composition may be a polymer composition having an elongation of at least 100% at 23°C, and capable of being stretched to twice its original length and held so for 1 minute, and recovering in the range of 50% to 100% within 1 minute after being released from stress. More specifically, the elastomeric polymer composition may recover in the range of 75% to 100% within 1 minute after being released from stress, and even more specifically, may recover in the range of 90% to 100% within 1 minute after being released from stress.
[0040]
[0047] The elastomer of the elastomeric polymer composition may comprise, consist essentially of, or consist of thermoset or thermoplastic elastomers such as acrylic rubber, butadiene rubber, butyl rubber, ethylene propylene rubber, ethylene propylene rubber diene monomer rubber, fluorocarbon rubber, isoprene rubber, nitrile rubber including hydrogenated nitrile rubber, polyurethane rubber, silicone rubber, and styrene block copolymer rubber (e.g., styrene butadiene rubber, styrene ethylene / butylene styrene rubber).
[0041]
[0048] In certain applications, the plastic molding platform 120 may be formed of a rigid polymer composition, such as a rigid thermoplastic polymer composition. The rigid polymer composition may be a polymer composition having a three-point flexural modulus, as measured by ASTM D790-10, of greater than 146,000 psi, and more particularly, greater than 200,000 psi. Additionally or alternatively, the rigid polymer composition may have a Shore D durometer hardness, as measured by ASTM D2240-05(2010), in the range of 55 to 90 Shore D durometer hardness.
[0042]
[0049] The hard polymer of the hard polymer composition may comprise, consist essentially of, or consist of a thermoset or thermoplastic hard polymer such as a polyolefin (e.g., polypropylene, polyethylene, acrylonitrile-butadiene-styrene), polycarbonate, polyamide, polyimide, polyurethane, polyester, and mixtures thereof.
[0043]
[0050] Appliqué 146 may be formed from a polymer composition, such as a thermoplastic polymer composition, that is initially extruded as a planar (two-dimensional) plastic sheet, particularly with a wall thickness of 0.1 mm to 1.5 mm, more particularly 0.25 mm to 1.0 mm. The extruded plastic sheet may be cut into separate planar sheet pieces / segments and thermoformed into a three-dimensional shape by vacuum (assisted) forming, i.e., forming the sheet pieces / segments with the assistance of negative (less than atmospheric) pressure, and / or pressure (assisted) forming, i.e., forming the sheet pieces / segments with the assistance of positive (greater than atmospheric) pressure, to provide appliqué 146 with pre-formed pleats 152 prior to forming plastic molding platform 120.
[0044]
[0051] Appliqué 146 may, more particularly, be formed from a rigid polymer composition, such as a rigid thermoplastic polymer composition. Similar to plastic molding platform 120, the rigid polymer of the rigid polymer composition may comprise, consist essentially of, or consist of a thermoset or thermoplastic rigid polymer, such as a polyolefin (e.g., polypropylene, polyethylene, acrylonitrile-butadiene-styrene), polycarbonate, polyamide, polyimide, polyurethane, polyester, and mixtures thereof.
[0045]
[0052] Referring now to Figure 4, there is shown an injection mold 200, or more specifically, an injection mold half, which, together with a mold cavity 202 having a molding surface 204, forms the exterior (front) surface 102 of article 100. Referring to Figure 5, there is shown a section 210 of the molding surface 204 of the molding cavity 202 of mold 200 of Figure 4, which is used to form the appliqué exterior (front) surface region 106 of article 100. As best shown in Figure 5, mold surface 204 includes an elongated stitch path support 214 that supports stitch paths P1-P4, which include pleat recesses 212 that receive pleats 152 of appliqué 146, as well as stitch recesses 216 that form stitches 160.
[0046]
[0053] Referring now to Figure 6, there is shown an injection mold 200, more specifically an injection mold half, that forms the outer (front) surface 102 of the article 100, along with the front side 148 of the thermoformed appliqué 146 (which forms the appliqué outer (front) surface region 106 of the front surface 102 of the article 100).
[0047]
[0054] 7, there is shown a section 170 of the exterior (front) surface region 106 of the appliqué 146 of FIG. 6 placed on the molding surface 204 of the molding cavity 202 of the mold 200. As shown, the thermoformed appliqué 146 includes pleats 152 and stitch path P, but the appliqué 146 does not include stitch lines L1-L4 and therefore does not include any stitches 160.
[0048]
[0055] Referring to FIG. 8, the back side 156 of the appliqué 146 is shown after the appliqué 146 has been loaded onto the molding surface 204 of the molding cavity 202 of the mold 200 .
[0049]
[0056] Once the appliqué 146 is loaded onto the molding surface 204 and into the molding cavity 202 of the mold 200, the mold 200 is closed and the plastic 200 that will form the platform 120 is injected into the molding cavity 202 of the mold 200. During injection, the plastic contacts the molding surface 204 at the platform front region 104 of the article 100 and the back side 156 of the appliqué 146 at the appliqué front region 106 of the article 106, to which the injected plastic bonds to the back side 156 of the appliqué 146. Additionally, due to molding pressure, the appliqué 146 deforms / stretches in the region 158 of the molding surface 204 that overlies the stitch recesses 216, entering the stitch recesses 216. As a result of the deformation / stretching of region 158 of appliqué 146 overlying stitch recess 216 into stitch recess 216, region 158 of appliqué 146 stress-whitens to form stitch 160 of a different, lighter color, i.e., closer to white (which may even be white), than the initial color of region 158 (and the boundary regions of stitch paths P1-P4) prior to the formation of stitch 160. Thus, given the placement of stitch recesses 216, such form a plurality of stitches 160 in stitch lines L1-L4 arranged end-to-end along stitch paths P1-P4.
[0050]
[0057] As best shown in FIG. 3, each of the plurality of fake stitch lines L1-L4 includes a respective plurality of fake stitches 160, each of the plurality of fake stitches 160 including a respective stress-whitened region 158 of the appliqué 146, and the plurality of fake stitch lines L1-L4 completely surround the plurality of standing pleats 152.
[0051]
[0058] Thus, a method for forming a plastic article with fake stitching is provided, the method including: inserting an applique 146 having a front side 148 and a back side 156 opposite the front side 148 into a molding cavity 202 of an injection mold 200, the applique 146 being formed from a thermoformed plastic sheet; injecting plastic into the molding cavity 202 to form an injection-molded plastic platform 120, the back side 156 of the applique 146 being joined to the platform 120; and forming at least one fake stitch line L1-L4 on the front side 148 of the applique 146, the at least one fake stitch line L1-L4 comprising a fake stitch 160, each of the fake stitches 160 comprising a stress-whitened region 158 of the applique 146 formed during the injection of plastic into the molding cavity 202.
[0052]
[0059] While preferred embodiments of the present invention have been described, it should be understood that various changes, adaptations, and modifications thereto can be made without departing from the spirit of the invention and the scope of the appended claims. Accordingly, the scope of the present invention should not be determined with reference to the above description, but should instead be determined with reference to the appended claims, along with their full scope of equivalents. Furthermore, it should be understood that the appended claims do not necessarily comprise the broadest scope of the invention that the applicant is entitled to claim, or the only way the invention may be claimed, or that all described features are required. [Explanation of symbols]
[0053] List of reference characters 10. Automobiles 12 Flooring 100 Plastic items 102 Outside (front) surface 104 Platform front area 106 Applique front area 120 Platform 122 Platform bottom wall / foundation wall 124 Platform peripheral rim 126 Front of platform 146 Applique 148 Applique front side 150 Applique Sections 152 Applique Pleats 154 Pleated front surface 156 Applique back side 158 Stress whitening area 160 stitches 162 stitch length 164 stitch width 166 stitch spacing 168 stitch path width 170 Applique Section 200 molds 202 Molding cavity 204 Molding surface 210 Molded Surface Section 212 Pleats recess 214 Stitch path support 216 Stitch recess L1~L4 stitch lines P1~P4 stitch paths S1~S4 Pleated side
Claims
1. A plastic article having faux stitching, an applique formed from a thermoformed plastic sheet, the applique having a front side and a back side opposite the front side; an injection molded plastic platform; the applique is insert molded into the platform with the rear side of the applique joined to the platform; at least one faux stitch line is formed on the front side of the appliqué; the at least one faux stitch line comprises a plurality of faux stitches; each faux stitch of the plurality of faux stitches comprises a stress-whitened area of the appliqué; Plastic items.
2. the front side of the applique further includes a plurality of standing pleats; The article of claim 1.
3. the at least one faux stitch line at least partially surrounds at least one standing pleat of the plurality of standing pleats; The article of claim 2.
4. the at least one faux stitch line is disposed between adjacent standing pleats of the plurality of standing pleats; The article of claim 2.
5. the at least one faux stitch line is disposed on at least one stitch path; the at least one stitch path is disposed between adjacent standing pleats of the plurality of standing pleats; the at least one stitch path borders the adjacent standing pleat; The article of claim 2.
6. the at least one faux stitch line comprises a plurality of faux stitch lines; each of the plurality of faux stitch lines comprises a respective plurality of the faux stitches; each faux stitch of the respective plurality of faux stitches comprising a respective stress-whitened area of the appliqué; the plurality of faux stitch lines completely surround the plurality of standing pleats; The article of claim 2.
7. each of the plurality of standing pleats having a matching polygonal shape; The article of claim 2.
8. The polygonal shape is a quadrilateral shape.
8. The article of claim 7.
9. the plurality of faux stitch lines are disposed on a plurality of respective stitch paths; each of the plurality of stitch paths is disposed between adjacent standing pleats of each of the plurality of standing pleats; each of the plurality of stitch paths completely bordering each of the adjacent standing pleats; 7. The article of claim 6.
10. the injection molded plastic platform is formed from an elastomer; and / or the injection molded plastic platform has a thickness in the range of 1.5 mm to 3.5 mm; The article of claim 1.
11. the thermoformed plastic sheet is formed from a thermoplastic; and / or The thermoformed plastic sheet has a thickness in the range of 0.1 mm to 1.5 mm. The article of claim 1.
12. the article has an exterior surface having an area provided by the front side of a plastic applique and an area provided by the front side of the injection molded plastic platform adjacent the front side of the plastic applique; The article of claim 1.
13. the faux stitches each comprising a respective stress-whitened region of the appliqué each have a longitudinal length in the range of 1 mm to 4 mm and / or a width perpendicular to said longitudinal length in the range of 0.1 mm to 0.9 mm; The article of claim 1.
14. the faux stitches each comprising a stress-whitened area of the appliqué have a different color than a border area of the appliqué that borders the faux stitch; The article of claim 1.
15. the plastic article is an automotive interior trim article; The article of claim 1.
16. The plastic article is a floor mat and / or a floor tray. The article of claim 1.
17. 1. A method of forming a plastic article with faux stitching, comprising: inserting an applique having a front side and a back side opposite the front side into a molding cavity of an injection mold, the applique being formed from a thermoformed plastic sheet; injecting plastic into the mold cavity to form an injection molded plastic platform, the rear side of the applique being bonded to the platform; forming at least one faux stitch line on the front side of the applique, the at least one faux stitch line comprising faux stitches, each of the faux stitches comprising a stress-whitened area of the applique formed during injection of the plastic into the mold cavity; method.
18. the front side of the applique further includes a plurality of standing pleats prior to insertion into the molding cavity of the injection mold; the at least one faux stitch line at least partially surrounds at least one pleat of the plurality of standing pleats; 18. The method of claim 17.
19. forming at least one faux stitch line on the front side of the applique, the at least one faux stitch line comprising faux stitches, each of the faux stitches comprising a stress-whitened area of the applique formed during injection of the plastic into the mold cavity, further comprising: forming a plurality of faux stitch lines on the front side of the applique, each of the plurality of faux stitch lines comprising a faux stitch, each of the faux stitches comprising a stress-whitened area of the applique formed during injection of the plastic into the mold cavity; the plurality of faux stitch lines completely surround the plurality of standing pleats; 20. The method of claim 18.
20. Furthermore, the article having an outer surface having an area provided by the front side of a plastic applique and an area provided by the front side of the injection molded plastic platform adjacent the front side of the plastic applique; 18. The method of claim 17.