US 10,357,909 B2 · Thermoset in-mold finishing film

Abstract

This invention relates to the manufacturing of durable thermoset in-mold finishing films (TIMFFs) combining in-mold decorating and in-mold durable exterior grade coating capabilities, to molded articles having TIMFFs adhering to their surfaces and both showing a decoration and providing protection, and to thermosetting resin formulations used in the manufacturing of TIMFFs. In some embodiments, the thermoset is prepared via polyurethane chemistry; the manufacturing process comprises reaction injection molding (RIM) with a specially designed mold; and articles having TIMFFs adhering to their surfaces include graphic panels for durable signage, structural graphics, molded flooring, prefabricated housing, aerospace structures and body panels, automotive structures and body panels, and marine structures and body panels. In addition to RIM, the TIMFF technology is also compatible with other processes, such as injection molding, compression molding, resin transfer molding, spin casting, rotational molding, thermoforming, roll lamination, use of a platen/laminate press, and blow molding.

Claims11

Dependent claims

A method for manufacturing an in-mold decorated and in-mold coated thermoset article, said method comprising:

(A) placing, on casting paper or texture plate, a durable coating film that is a third B-stage polyurethane resin, said third B-stage polyurethane resin optionally containing an additive, a finish, or a combination or mixture thereof, selected to enhance the durability of the coated surface of the finished article by improving its scratch resistance, wherein the casting paper or texture plate are located in a mold;
(B) applying a printable film comprising a reactive and printable resin to the durable coating film, thereby to form the printable film, where (i) said reactive and printable resin is a first B-stage polyurethane resin and a second B-stage polyurethane resin;
(C) optionally printing an image, pattern, text, indicia, or combination thereof onto said printable resin;
(D) filling the mold with an article resin, the article resin is a fourth B-stage polyurethane resin;
and (E) performing a curing reaction to thereby form an integrally bonded molded article.

2 more elements

Dependencies are inferred from the claim text.

Thermoset in-mold finishing film

Life of this patent

Thermoset in-mold finishing film

Life of this patent

Abstract

Claims11