In-mold decorative applique with textured surface

Patent metadata

Field	Value
Publication number	US-9283701-B2
Application number	US-84122110-A
Country	US
Kind code	B2
Filing date	Jul 22, 2010
Priority date	Jul 22, 2010
Publication date	Mar 15, 2016
Grant date	Mar 15, 2016

Abstract

A plastic-molded automotive interior trim component has a curvilinear finished surface with a relatively flat portion and a relatively curved portion. A decorative film subcomponent has an outer surface and an inner surface, wherein at least the outer surface is pigmented with a desired color of the finished surface. Prior to incorporation into the plastic molded component, the decorative film subcomponent has a shape generally conforming to the curvilinear finished surface and is substantially smooth. A structural backing member is in-mold laminated with the decorative film subcomponent, wherein the structural backing member is formed by injection molding a backing material against the inner surface of the decorative film subcomponent in a mold having a film-receiving surface with a three-dimensional texture that receives the decorative film subcomponent. The texture shapes the decorative film subcomponent with an embossed pattern having a substantially uniform, undistorted appearance on at least part of the relatively flat portion and at least part of the relatively curved portion.

First claim

What is claimed is:

1. A plastic-molded automotive interior trim component having a curvilinear finished surface with a relatively flat portion and a relatively curved portion, comprising:
a decorative film subcomponent with an outer surface and an inner surface, wherein at least the outer surface is pigmented with a desired color of the finished surface, wherein prior to incorporation into the plastic molded component the decorative film subcomponent has a shape generally conforming to the curvilinear finished surface, and wherein prior to incorporation into the plastic molded component the outer surface is substantially smooth; and
a structural backing member which is in-mold laminated with the decorative film subcomponent, wherein the structural backing member is formed by injection molding a backing material against the inner surface of the decorative film subcomponent in a mold having a film-receiving surface having a three-dimensional texture that receives the decorative film subcomponent and shapes the decorative film subcomponent with an embossed pattern having a substantially uniform, undistorted appearance on at least part of the relatively flat portion and at least part of the relatively curved portion.

2. The component of claim 1 wherein the embossed pattern of the decorative film subcomponent is comprised of a regular, grid-like pattern repeating across substantially all of the outer surface.

3. The component of claim 1 wherein the relatively curved portion includes a deep draw contour.

4. The component of claim 1 wherein the three-dimensional texture includes a relief forming a graphic element at the relatively flat portion, and wherein the embossed pattern continues over the graphic element.

5. The component of claim 4 wherein the decorative film subcomponent further comprises a contrasting pigment on the substantially smooth outer surface at the relatively flat portion corresponding to the relief so that the graphic element has a distinctive color and three-dimensional texture.

6. An automotive vehicle interior trim structure comprising:
a plurality of abutting interior trim components each having a matched embossed pattern, wherein at least one interior trim component has a curvilinear finished surface with a relatively flat portion and a relatively curved portion, and wherein the at least one interior trim component includes:
a decorative film subcomponent with an outer surface and an inner surface, wherein at least the outer surface is pigmented with a desired color of the finished surface, wherein prior to incorporation into the plastic molded component the decorative film subcomponent has a shape generally conforming to the curvilinear finished surface, and wherein prior to incorporation into the plastic molded component the outer surface is substantially smooth; and
a structural backing member which is in-mold laminated with the decorative film subcomponent, wherein the structural backing member is formed by injection molding a backing material against the inner surface of the decorative film subcomponent in a mold having a film-receiving surface having a three-dimensional texture that receives the decorative film subcomponent and shapes the decorative film subcomponent with an embossed pattern having a substantially uniform, undistorted appearance on at least part of the relatively flat portion and at least part of the relatively curved portion.

Assignees

• Doan Linh N
• Holland James P
• Laird Kenneth S
• Swank Stacy L
• Crist Jeffrey B
• Smith Warwick J
• Barraza Aileen N
• Ford Global Tech Llc

Inventors

• Doan Linh N
• Holland James P
• Laird Kenneth S
• Swank Stacy L
• Crist Jeffrey B
• Smith Warwick J
• Barraza Aileen N

Classifications

• B32B2307/75

  Printability · CPC title

• B29K2105/256

  Sheets, plates, blanks or films · CPC title

• Y10T428/24612

  Composite web or sheet · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title

• B29C2045/14213

  deforming by gas or fluid pressure in the mould cavity · CPC title