Manufacturing method for an aesthetic structural part
AssigneeThermo King Corporation
InventorSelvam Packiarajan
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Abstract
An aesthetic structural product is provided that incorporates high structural strength and high-gloss finish through a streamlined manufacturing process combining hybrid molding with an overlay of decorative film. The method includes preheating a composite sheet, applying a decorative film to the composite sheet through hot stamping, thermoforming the composite sheet to a desired shape, and overmolding desired features using a resin which is compatible with the composite of the composite sheet. The method may be performed in varying order, such as overmolding and/or thermoforming the composite sheet prior to hot-stamping the decorative film to the composite sheet.
Claims11
A method of manufacturing an aesthetic structural plastic part, comprising:
- providing a thermoplastic composite sheet, wherein the thermoplastic composite sheet includes a thermoplastic resin and fibers;
- providing a decorative film, wherein the decorative film includes a top layer, a pigmented middle layer, and a bottom adhesion layer;
- hot-stamping the decorative film to the thermoplastic composite sheet, wherein the bottom adhesion layer is in contact with the thermoplastic composite sheet;
- thermoforming the composite sheet, and overmolding a thermoplastic material to the composite sheet,
- wherein overmolding a thermoplastic material to the composite sheet comprises forming one or more mounting features in the thermoplastic material, and
- the aesthetic structural part includes the decorative film, the composite sheet, and the one or more mounting features.
Dependencies are inferred from the claim text.