CA2182727C - Method of making a molded article having a film layer - Google Patents
Method of making a molded article having a film layer Download PDFInfo
- Publication number
- CA2182727C CA2182727C CA002182727A CA2182727A CA2182727C CA 2182727 C CA2182727 C CA 2182727C CA 002182727 A CA002182727 A CA 002182727A CA 2182727 A CA2182727 A CA 2182727A CA 2182727 C CA2182727 C CA 2182727C
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- CA
- Canada
- Prior art keywords
- mold
- preform
- film
- article
- undercut
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/10—Forming by pressure difference, e.g. vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/78—Moulding material on one side only of the preformed part
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
The disclosure describes a method of making a molded article having a film layer on its exterior surface that provides a surface finish to the article; the method consists in first placing a thermoplastic film in a two-partmold having a negative recessed border undercut in one of its part and in vacuum forming, under heat conditions, the film to make a preform having inward folded edge having a shape corresponding to that of the recessed border undercut. After removing the preform from the mold, part of the preform edge is trimmed to leave an inward peripheral edge along the preform which is then placed in a second mold wherein molten plastic is blown or injected; the plastic of the peripheral edge melts with the plastic to provide an intimate bonding at the peripheral edge of the article.
Description
~' Z1827~7 TITLE OF THE INVENTION
Method of making a molded article having a film layer.
FIELD OF THE INVENTION
The present invention perlains to a method of making a molded 5 article having a film layer on its exterior surface to provide a surface finish to the article.
BACKGROUND OF THE INVENTION
In-mold decorated parts are manuFactured by injecting a suitable II,t:,,,,ul,la:,lic material into a mold at its molten state behind a 10 decorated film. However, parts molded in this manner have one drawback in that, along the sepd,dli"g lines or edges of the article, the film, if subjected to rubbing during use, is easily scratched or pealed off.
In cases where the decorated film is made by a themmo-forming process, such hlm is heated and vacuum formed onto a mold. The preform 15 is then removed and placed in an injection mold where molten resin is injected to form a rough pattern-bearing part. The Se~Jdl ~llil ,g lines of thispart are then trimmed. In some cases, the part contour has less than a sdli~rd-.loly aspect due to either film damage and/or visible knife cuts resulting from edge trimming.
~ 218272~
OBJECTS AND STATEMENT OF THE INVENTION
It is an object of the present invention to provide 8 method of making a molded article having a film layer on its exterior surface to provide a surface finish to the article, which method overcomes the above problems 5 of present methods and provides better quality aspect to the part contour.
It is also an object of the present invention to provide a method of manufacturing an article using a preform having its edges folded towards the the interior so that, at the Se,l:ldl dLil ~9 lines of the article, the film is not exposed to accidental external shear or rubbing.
it is a further object of the present invention to achieve a molded article wherein the plastic material is co",,udliL,le with the film material so that the adhesion obtained during molding of the plastic material in the molten state, behind the film, results in an intimate bonding.
It is still an object of the present invention to provide a method of making a molded article having a film layer on its exterior surface wherein the folded edge of the preform prevents resin of the molding operation from escaping behind the film's exterior surface.
The present invention therefore relates to a method of making a molded article having a layer on its exterior surface to provide a surface finish to the article which comprises the steps of:
- placing a lhel ~ui~la~Li~, film in a two-part mold having a negative recessed border undercut in one of its parts;
- vacuum forming, under heat conditions, the film to make a preform having an inward folded edge having a shape 2 5 Cul I ~:~,uondil l9 to that of the recessed border undercut;
- removing the preform from the mold;
- trimming a part of the folded edge so as to leave an inward peripheral edge along the preform;
- placing the preform in a second mold; and - processi"g molten plastic in this mold whereby the 5peripheral edse melts with the molten plastic to provide an intimate bonding at the peripheral edge of the article.
In one preferred form of the invention, the preform material and the plastic material are the same, in which case one preferred material is acrylonitrile-butadiene-styrene (ABS) polymer.
10Also, the outer surface of the film will preferably bear a pattern printed thereon.
Other objects and further scope of ~ ' b ' 'y of the present invention will become apparent from the detailed des~ lion given l~e~t~i"dll~ . It should be understood, however, that this detailed desu, i~liun, 15while indicating preferred e"lbodi",e"t~ of the invention, is given by way of illustration only, since various changes and ",odiricdlions within the spirit and scope of the invention will become apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view of one of a two-part mold for 20making a preform;
Figure 2 is a cross-sectional view taken along lines 2-2 of figure 1;
Figure 3 is a cross-sectional view of the preform;
~182~27 Figure 4 is a perspective view of the molded article;
Figure 5 is a cross-sectional view of the molded article; and Figure 6 is an enlarged cross sectional view taken along lines 6~ of figure 4.
5 DtSCfil. I ION OF PRE~tKRtu EMBODIMENTS
An e",bo.li",e"t of a molding method according to the present invention is now described.
A thermo-plastic film is first placed in a two-part mold, one part being illustrated as the male part 10 in figure 1. The thermo-plastic film is an extruded material which has a thickness of between 0.015 inch to 0.030 inch. It can be made of any type of resin, such as poly~ bolldte, acrylonitrile-butadiene-styrene (ABS), polyvinyl chloride (PVC), thermoplastic olefin (TPO) or polystyrene (HIPS). The interior or exterior surface of the film has, in most cases, an ink or paint decoration. As it is well 15 known in the art, the Lht:llllurc)lllli"g temperatures are critical for the stretching of films; these temperatures should be constant for uniform stretching and they depend on the resins used; for example, 4003F for ABS, 360~F for TPO. One ll,e""uroll"i"g process having great precision is the present high pressure forming (HPF) process wherein a jet of air is blown on 2 o the film which is then sucked to meet the male part of a mold forming a bulb and the female part completes the operation for precise forming.
Male part 10 has an upper surface 12 having a configuration co"~,uondi"g to that of the article to be made. This mold part 10 is ~ Q ') q 'J 7 ul 1~11 dl~ d by an undercut 14 defined by a series of surfaces 16, 18 and 20 extending all along the peripheral edges of the part.
The thenmo-plastic film is heated and placed over the male part 10 and is adhered to it by a vacuum created through a series of suction holes 22 which are located at various areas through the mold part 10 including the undercut area 14.
The thickness of the films used for the preform vary between .015 to .030 inch with a preferred thickness of .020 (as stated above) which ensures the protection of the ink or paint on the film during the injection of plastic in a molten state behind the film. Preferably, the time of cycle of the preform operation of a film layer should not exceed 60 seconds.
The film is removed from the mold by air injection from the inside of the mold and, in some cases, this is combined with air vacuum from the outside to thus free the film from its engd~ "e"l to the II,e,,,,uru,,~fi,,gmold. A preform 24 is thus obtained having a configuration uO~rullllill9 to that of the II ,~n ~ ~urul l, ,il ,9 mold with a folded area consisting of edges 26, 28 and 30. It is noted that a film of .020 inch is sufficiently flexible to avoid tearing during its removal.
There follows a trimming operation which consists in removing 2 o folded edges 28 and 30 so as to leave a preform having folded edge 26 only.
The preform 24 may then be placed in a conventional injection mold where the folded edge 26 is defonmed to define two edge portions 26a and 26b (see figure 6). Molten resin is then injected to form a laminate article 40 (see figures 4 and 5) having a first layer consisting of the preform 24 and a second layer 32 of molten material. The folded edge portions 26a and 26b serve to retain the molten resin during the forming operation. If the ~ 2182727 plastic material 32 is identical to the material used for the film 24, no transition is seen in the molded part at 34, providing of course that the materials are of the same colour. Thus, the article molded is flash-free in that no trimming is needed around the parting lines since the injected 5 U l~l l l lu,uld~ i resin fills the article from the interior and the film prevents the molten resin from escaping through the mold parting lines.
The required temperature so that there be fusion of the injected plastic while, at the same time, partial fusion of the preform carrying a pattern for a maximal adhesion in the case of ABS is between 400~F and lO 430~F. Obviously, these temperatures will vary with the resins used.
Preferably, the plastic used in the injection mold will be the same in most cases as that used for the preform.
Although the invention has been described above with respect with one specific form, it will be evident to a person skilled in the art that it 15 may be modified and refined in various ways.
First, a blow molding process may be used instead of the injection process described above; for example, a storage cover for motor marines is one made with the blow molding process wherein a preform lies on the exterior face thereof.
Secondly, the molded article 40 illustrated in the drawings does not display any openings. However, the present method may also be applied to such articles where openings are provided. For example, the molded article may consist of the hood of a small track-driven vehicle or that of a water vehicle on which ventilation openings may be required; in which case an undercut, as described above, is provided for each opening at all ~ 2~82727 parting lines. Similar opening-bearing articles may consist of vehicle wheel covers, aerated cyclist helmets, etc.
It is therefore wished to have it u"der~lood that the present invention should not be limited in scope, except by the terms of the following 5 claims.
Method of making a molded article having a film layer.
FIELD OF THE INVENTION
The present invention perlains to a method of making a molded 5 article having a film layer on its exterior surface to provide a surface finish to the article.
BACKGROUND OF THE INVENTION
In-mold decorated parts are manuFactured by injecting a suitable II,t:,,,,ul,la:,lic material into a mold at its molten state behind a 10 decorated film. However, parts molded in this manner have one drawback in that, along the sepd,dli"g lines or edges of the article, the film, if subjected to rubbing during use, is easily scratched or pealed off.
In cases where the decorated film is made by a themmo-forming process, such hlm is heated and vacuum formed onto a mold. The preform 15 is then removed and placed in an injection mold where molten resin is injected to form a rough pattern-bearing part. The Se~Jdl ~llil ,g lines of thispart are then trimmed. In some cases, the part contour has less than a sdli~rd-.loly aspect due to either film damage and/or visible knife cuts resulting from edge trimming.
~ 218272~
OBJECTS AND STATEMENT OF THE INVENTION
It is an object of the present invention to provide 8 method of making a molded article having a film layer on its exterior surface to provide a surface finish to the article, which method overcomes the above problems 5 of present methods and provides better quality aspect to the part contour.
It is also an object of the present invention to provide a method of manufacturing an article using a preform having its edges folded towards the the interior so that, at the Se,l:ldl dLil ~9 lines of the article, the film is not exposed to accidental external shear or rubbing.
it is a further object of the present invention to achieve a molded article wherein the plastic material is co",,udliL,le with the film material so that the adhesion obtained during molding of the plastic material in the molten state, behind the film, results in an intimate bonding.
It is still an object of the present invention to provide a method of making a molded article having a film layer on its exterior surface wherein the folded edge of the preform prevents resin of the molding operation from escaping behind the film's exterior surface.
The present invention therefore relates to a method of making a molded article having a layer on its exterior surface to provide a surface finish to the article which comprises the steps of:
- placing a lhel ~ui~la~Li~, film in a two-part mold having a negative recessed border undercut in one of its parts;
- vacuum forming, under heat conditions, the film to make a preform having an inward folded edge having a shape 2 5 Cul I ~:~,uondil l9 to that of the recessed border undercut;
- removing the preform from the mold;
- trimming a part of the folded edge so as to leave an inward peripheral edge along the preform;
- placing the preform in a second mold; and - processi"g molten plastic in this mold whereby the 5peripheral edse melts with the molten plastic to provide an intimate bonding at the peripheral edge of the article.
In one preferred form of the invention, the preform material and the plastic material are the same, in which case one preferred material is acrylonitrile-butadiene-styrene (ABS) polymer.
10Also, the outer surface of the film will preferably bear a pattern printed thereon.
Other objects and further scope of ~ ' b ' 'y of the present invention will become apparent from the detailed des~ lion given l~e~t~i"dll~ . It should be understood, however, that this detailed desu, i~liun, 15while indicating preferred e"lbodi",e"t~ of the invention, is given by way of illustration only, since various changes and ",odiricdlions within the spirit and scope of the invention will become apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view of one of a two-part mold for 20making a preform;
Figure 2 is a cross-sectional view taken along lines 2-2 of figure 1;
Figure 3 is a cross-sectional view of the preform;
~182~27 Figure 4 is a perspective view of the molded article;
Figure 5 is a cross-sectional view of the molded article; and Figure 6 is an enlarged cross sectional view taken along lines 6~ of figure 4.
5 DtSCfil. I ION OF PRE~tKRtu EMBODIMENTS
An e",bo.li",e"t of a molding method according to the present invention is now described.
A thermo-plastic film is first placed in a two-part mold, one part being illustrated as the male part 10 in figure 1. The thermo-plastic film is an extruded material which has a thickness of between 0.015 inch to 0.030 inch. It can be made of any type of resin, such as poly~ bolldte, acrylonitrile-butadiene-styrene (ABS), polyvinyl chloride (PVC), thermoplastic olefin (TPO) or polystyrene (HIPS). The interior or exterior surface of the film has, in most cases, an ink or paint decoration. As it is well 15 known in the art, the Lht:llllurc)lllli"g temperatures are critical for the stretching of films; these temperatures should be constant for uniform stretching and they depend on the resins used; for example, 4003F for ABS, 360~F for TPO. One ll,e""uroll"i"g process having great precision is the present high pressure forming (HPF) process wherein a jet of air is blown on 2 o the film which is then sucked to meet the male part of a mold forming a bulb and the female part completes the operation for precise forming.
Male part 10 has an upper surface 12 having a configuration co"~,uondi"g to that of the article to be made. This mold part 10 is ~ Q ') q 'J 7 ul 1~11 dl~ d by an undercut 14 defined by a series of surfaces 16, 18 and 20 extending all along the peripheral edges of the part.
The thenmo-plastic film is heated and placed over the male part 10 and is adhered to it by a vacuum created through a series of suction holes 22 which are located at various areas through the mold part 10 including the undercut area 14.
The thickness of the films used for the preform vary between .015 to .030 inch with a preferred thickness of .020 (as stated above) which ensures the protection of the ink or paint on the film during the injection of plastic in a molten state behind the film. Preferably, the time of cycle of the preform operation of a film layer should not exceed 60 seconds.
The film is removed from the mold by air injection from the inside of the mold and, in some cases, this is combined with air vacuum from the outside to thus free the film from its engd~ "e"l to the II,e,,,,uru,,~fi,,gmold. A preform 24 is thus obtained having a configuration uO~rullllill9 to that of the II ,~n ~ ~urul l, ,il ,9 mold with a folded area consisting of edges 26, 28 and 30. It is noted that a film of .020 inch is sufficiently flexible to avoid tearing during its removal.
There follows a trimming operation which consists in removing 2 o folded edges 28 and 30 so as to leave a preform having folded edge 26 only.
The preform 24 may then be placed in a conventional injection mold where the folded edge 26 is defonmed to define two edge portions 26a and 26b (see figure 6). Molten resin is then injected to form a laminate article 40 (see figures 4 and 5) having a first layer consisting of the preform 24 and a second layer 32 of molten material. The folded edge portions 26a and 26b serve to retain the molten resin during the forming operation. If the ~ 2182727 plastic material 32 is identical to the material used for the film 24, no transition is seen in the molded part at 34, providing of course that the materials are of the same colour. Thus, the article molded is flash-free in that no trimming is needed around the parting lines since the injected 5 U l~l l l lu,uld~ i resin fills the article from the interior and the film prevents the molten resin from escaping through the mold parting lines.
The required temperature so that there be fusion of the injected plastic while, at the same time, partial fusion of the preform carrying a pattern for a maximal adhesion in the case of ABS is between 400~F and lO 430~F. Obviously, these temperatures will vary with the resins used.
Preferably, the plastic used in the injection mold will be the same in most cases as that used for the preform.
Although the invention has been described above with respect with one specific form, it will be evident to a person skilled in the art that it 15 may be modified and refined in various ways.
First, a blow molding process may be used instead of the injection process described above; for example, a storage cover for motor marines is one made with the blow molding process wherein a preform lies on the exterior face thereof.
Secondly, the molded article 40 illustrated in the drawings does not display any openings. However, the present method may also be applied to such articles where openings are provided. For example, the molded article may consist of the hood of a small track-driven vehicle or that of a water vehicle on which ventilation openings may be required; in which case an undercut, as described above, is provided for each opening at all ~ 2~82727 parting lines. Similar opening-bearing articles may consist of vehicle wheel covers, aerated cyclist helmets, etc.
It is therefore wished to have it u"der~lood that the present invention should not be limited in scope, except by the terms of the following 5 claims.
Claims (11)
1. A method of making a molded article having a film layer on its exterior surface to provide a surface finish to the article, comprising the steps of:
- placing a thermoplastic film in a two-part mold having a negative recessed border undercut in one part of said mold;
- vacuum forming, under heat conditions, said film to make a preform having an inward folded edge having a shape corresponding to that of said recessed border undercut;
- removing said preform from said mold;
- trimming a part of said folded edge so as to leave an inward peripheral edge along said preform;
- placing said preform in a second mold; and - processing molten plastic in said second mold whereby said peripheral edge melts with the molten plastic to provide an intimate bonding at the peripheral edge of the article.
- placing a thermoplastic film in a two-part mold having a negative recessed border undercut in one part of said mold;
- vacuum forming, under heat conditions, said film to make a preform having an inward folded edge having a shape corresponding to that of said recessed border undercut;
- removing said preform from said mold;
- trimming a part of said folded edge so as to leave an inward peripheral edge along said preform;
- placing said preform in a second mold; and - processing molten plastic in said second mold whereby said peripheral edge melts with the molten plastic to provide an intimate bonding at the peripheral edge of the article.
2. A method as defined in claim 1, wherein said thermoplastic film and said molten plastic consist of the same material.
3. A method as defined in claim 2, wherein said material is acrylonytrile-butadiene-styrene (ABS) polymer.
4. A method as defined in claim 3, wherein the temperature of said molten plastic is between 400°F to 430°F.
5. A method as defined in claim 4, wherein said vacuum forming is conducted at about 400°F.
6. A method as defined in claim 1, wherein said film layer has a thickness of between 0.015 inch to 0.030 inch and is flexible.
7. A method as defined in claim 6, wherein said preform is removed from said first mold by internal air ejection and by external suction.
8. A method as defined in claim 7, wherein said vacuum forming is carried out at high pressure and consists in blowing hot air on said film and in aspiring said film on said one part of said two-part mold.
9. A method as defined in claim 1, wherein said processing step is an injection molding step.
10. A method as defined in claim 1, wherein said processing step is a blow molding step.
11. A method of making a molded article having a film layer on its exterior surface to provide a surface finish to the article, said articlehaving one or more openings, comprising the steps of.
- placing a thermoplastic film in a two-part opening-bearing mold having a negative recessed border undercut in each opening of one part of said mold;
- vacuum forming, under heat conditions, said film to make a preform having, at each opening, an inward folded edge having a shape corresponding to that of an associated recessed border undercut;
- removing said preform from said mold;
- trimming a part of said folded edge so as to leave an inward peripheral edge at each opening and border of said preform;
placing said preform in an injection mold; and injecting molten plastic in said injection mold whereby all peripheral edges melt with the injected plastic to provide an intimate bonding at the peripheral edges of the article.
- placing a thermoplastic film in a two-part opening-bearing mold having a negative recessed border undercut in each opening of one part of said mold;
- vacuum forming, under heat conditions, said film to make a preform having, at each opening, an inward folded edge having a shape corresponding to that of an associated recessed border undercut;
- removing said preform from said mold;
- trimming a part of said folded edge so as to leave an inward peripheral edge at each opening and border of said preform;
placing said preform in an injection mold; and injecting molten plastic in said injection mold whereby all peripheral edges melt with the injected plastic to provide an intimate bonding at the peripheral edges of the article.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002182727A CA2182727C (en) | 1996-08-05 | 1996-08-05 | Method of making a molded article having a film layer |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002182727A CA2182727C (en) | 1996-08-05 | 1996-08-05 | Method of making a molded article having a film layer |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2182727A1 CA2182727A1 (en) | 1998-02-06 |
| CA2182727C true CA2182727C (en) | 2000-04-25 |
Family
ID=4158701
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002182727A Expired - Fee Related CA2182727C (en) | 1996-08-05 | 1996-08-05 | Method of making a molded article having a film layer |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2182727C (en) |
-
1996
- 1996-08-05 CA CA002182727A patent/CA2182727C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2182727A1 (en) | 1998-02-06 |
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| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |