In-mold apparatus and method for decorative application

An apparatus, comprising:

• a matched die mold comprising a male die mold and a female die mold wherein the male die mold comprises a first contoured surface and the female die mold comprises a second contoured surface;
• a frame which defines an opening wherein the frame is positioned between the male die mold and the female die mold such that the frame is adapted to position a film layer across the opening and the opening is positioned in alignment with at least one of the first contoured surface and the second contoured surface, wherein:
• the frame comprises a first sub-frame and a second sub-frame component;
• the first sub-frame component and the second sub-frame component are configured to secure a film layer to extend across the opening defined by the frame;
• the film layer overlies the first sub-frame component;
• and
• at least one of a seal positioned between the film layer and the second sub-frame component and a die seal positioned between the second sub-frame component and one of the male die mold and the female die mold.

An apparatus, comprising:

• a matched die mold comprising a male die mold and a female die mold wherein the male die mold comprises a first contoured surface and the female die mold comprises a second contoured surface;
• a frame which defines an opening wherein the frame is positioned between the male die mold and the female die mold such that the frame is adapted to position a film layer across the opening and the opening is positioned in alignment with at least one of the first contoured surface and the second contoured;
• and
• a releasable clamp assembly secured to the frame and to one of the male die mold and the female die mold.

A method for making a contoured composite panel, comprising the step of:

• positioning a film layer extending across an opening defined by a frame;
• positioning the frame between a male die mold and a female die mold, wherein:
• the male die mold defines a first contoured surface;
• the female die mold defines a second contoured surface;
• and
• the opening with the film layer extending across the opening is aligned with one of the first contoured surface and the second contoured surface;
• positioning one of:
• a first pin, through a first pin hole defined by the frame wherein the first pin extends from the male die mold aligning the film layer and the opening of the frame with the first contoured surface, and
• a second pin, through a second pin hole defined by the frame wherein the second pin extends from the female die mold aligning the film layer and the opening of the frame with the second contoured surface;
• positioning a composite layup between the male die mold and the female die mold;
• applying a compressive force onto the composite layup and onto the film layer with the male die mold and the female die mold;
• and
• applying heat to the composite layup and the film layer.