In-Mold Lamination Of Decorative Products

Abstract

A method of manufacturing decorative plastic composites having a decorative layer, a backing layer and a clear outer layer which provides exceptional “depth of image” is disclosed. Decorative or protective appliqués' having a wide range of decorative patterns may be formed by injection molding a backing layer behind and a clear outer layer on the top surface of a thin foil, film, fabric or veneer. A method is also disclosed for coating the exposed surface of the decorative layer between injection of the backing and outer layers to impart a desired visual effect or repair the surface. Use of multiple layers of decorative film, clear plastic and colored/opaque plastic is also disclosed to provide distinguishing visual effects.

1 . A method of forming an appliqué or trim product comprising:
 providing a first decorative layer and a second decorative layer; and 
 injection molding a clear plastic transparent layer between said first and said second decorative layers, wherein said first decorative layer and said second decorative layers are different from one another and wherein said first and/or said second decorative layer comprises one or more of metal, wood, paper, cloth, a film, a foil, a laminate, a veneer, paint or fabric and wherein said first and/or said second decorative layers include a transparent portion. 
 
     
     
         2 . The method of  claim 1  further comprising injection molding a second plastic layer behind said second decorative layer. 
     
     
         3 . The method of  claim 2  wherein said second plastic layer is a clear plastic. 
     
     
         4 . The method of  claim 2  wherein said second plastic layer comprises a colored or opaque plastic. 
     
     
         5 . The method of  claim 2  wherein said second plastic layer comprises polycarbonate, acrylonitrile-butadiene-styrene or a combination thereof.