# US 2019/0168429 A1 · Polymer Sealed In-Mold Decoration and Method of Manufacture

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- Number: US 2019/0168429 A1
- Document ID: US20190168429A1
- Status: Published application
- Kind: A1
- Application number: 15/997,938
- Filed: 2018-06-05
- Published: 2019-06-06
- Earliest claimed: 2013-02-26
- Assignees: Curnutt Products, LLC
- Applicants: Curnutt Products, LLC
- Inventors: Timothy P. Curnutt
- Web page: https://patentgrep.com/patent/US20190168429A1

## CPC

- B29C 45/0003: {of successively moulded portions rigidly joined to each other}
- B29C 45/14688: {Coating articles provided with a decoration}
- B29C 45/1671: {with an insert}
- B32B 1/00: Layered products having a non-planar shape
- B32B 3/02: characterised by features of form at particular places, e.g. in edge regions {(non-uniform thickness B32B3/263)}
- B32B 3/04: characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material}
- B32B 15/08: of synthetic resin
- B32B 27/06: as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)}
- B32B 27/08: of synthetic resin
- B32B 27/20: using fillers, pigments, thixotroping agents
- B29L 2009/00: Layered products
- B32B 2307/714: Inert, i.e. inert to chemical degradation, corrosion
- B32B 2451/00: Decorative or ornamental articles
- B32B 2601/00: Upholstery
- Y10T 428/26: Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
- Y10T 428/31504: Composite [nonstructural laminate]
- Y10T 428/31678: Of metal
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An injection molded product formed from an inner layer, or substrate, to which an aesthetic IMD layer is bonded during a first injection molding process, leaving a portion of the substrate exposed about the perimeter(s) of the substrate. A transparent outer layer, or overmold, is then injection molded over the top of the IMD layer and substrate, bonding substantially to the IMD layer and to the substrate where it remains exposed following the first injection molding. The process of forming a product through the disclosed two-step injection molding process creates a customizable, aesthetic product with an aesthetic IMD layer completely encapsulated between the substrate and a clear overmold in such a way to protect the IMD layer from the environment in which the product is used.

## Claims

### Claim 1

A polymer sealed in-mold decoration comprising:
an in-mold decoration layer;
a first molded layer attached to said in-mold decoration layer with an exposed portion of said first molded layer extending beyond said in-mold decoration layer;
a second molded layer covering said in-mold decoration layer and attached to said exposed portion of said first molded layer;
wherein said in-mold decoration layer is sealed between said first molded layer and said second molded layer.

### Claim 2 (depends on 1)

The polymer sealed in-mold decoration of claim 1, wherein said first molded layer further comprises a second exposed portion of said first molded layer, said second exposed portion extending beyond said in-mold decoration layer.

### Claim 3 (depends on 2)

The polymer sealed in-mold decoration of claim 2, wherein said second molded layer is attached to said second exposed portion of said first molded layer.

### Claim 4 (depends on 3)

The polymer sealed in-mold decoration of claim 3, wherein said in-mold decoration layer is hermetically sealed between said first molded layer and said second molded layer.

### Claim 5

A polymer sealed in-mold decoration comprising:
an in-mold decoration layer;
a first molded layer attached to said in-mold decoration layer with an exposed external portion of said first molded layer extending past said in mold-decoration, formed by a first injection of a substrate material onto and past said in-mold decoration layer;
a second molded layer attached to said in-mold decoration layer and said exposed external portion of said first molded layer, formed by an injection of an overmold material onto said in-mold decoration layer and said exposed external portion of said first molded layer; and
wherein said in-mold decoration layer is attached to said first molded layer and said second molded layer and is sealed between said first molded layer and said second molded layer.

### Claim 6 (depends on 5)

The polymer sealed in-mold decoration of claim 5, wherein said in-mold decoration layer is bonded to said first molded layer and said second molded layer and said first molded layer is bonded to said second molded layer.

### Claim 7 (depends on 5)

The polymer sealed in-mold decoration of claim 5, wherein said first molded layer further comprises an exposed internal portion of said first molded layer, said exposed internal portion extending past said in-mold decoration layer.

### Claim 8 (depends on 7)

The polymer sealed in-mold decoration of claim 7, wherein said second molded layer is attached to said exposed internal portion of said first molded layer.

### Claim 9 (depends on 8)

The polymer sealed in-mold decoration of claim 8, wherein said in-mold decoration layer is hermetically sealed between said first molded layer and said second molded layer.

### Claim 10 (depends on 9)

The polymer sealed in-mold decoration of claim 9, wherein said in-mold decoration layer is bonded to said first molded layer and said second molded layer and said first molded layer is bonded to said second molded layer.

### Claim 11

A polymer sealed in-mold decoration comprising:
an in-mold decoration having an in-mold decoration surface area;
a substrate having a substrate surface area larger than said substrate surface area and an external perimeter, said substrate is bonded to said in-mold decoration, thereby forming an exposed external portion of said substrate extending between said in-mold decoration and said external perimeter of said substrate;
an overmold bonded to said in-mold decoration and said exposed external portion of said substrate;
wherein said in-mold decoration is bonded to said substrate and said overmold and is sealed between said substrate and said overmold.

### Claim 12 (depends on 11)

The polymer sealed in-mold decoration of claim 11, wherein said substrate, said in-mold decoration, and said overmold form a single seamless unitary part.

### Claim 13 (depends on 11)

The polymer sealed in-mold decoration of claim 11, wherein said substrate and said overmold are polymerized together.

### Claim 14 (depends on 11)

The polymer sealed in-mold decoration of claim 11, wherein said substrate, said in-mold decoration, and said overmold are polymerized together to form a single seamless unitary part.

### Claim 15 (depends on 11)

The polymer sealed in-mold decoration of claim 11, wherein said substrate further comprises an internal perimeter and an exposed internal portion of said substrate extending between said in-mold decoration and said internal perimeter of said substrate.

### Claim 16 (depends on 15)

The polymer sealed in-mold decoration of claim 15, wherein said overmold is bonded to said exposed internal portion of said substrate.

### Claim 17 (depends on 16)

The polymer sealed in-mold decoration of claim 16, wherein said in-mold decoration layer is hermetically sealed between said substrate and said overmold.

### Claim 18 (depends on 16)

The polymer sealed in-mold decoration of claim 16, wherein said substrate, said in-mold decoration, and said overmold form a single seamless unitary part.

### Claim 19 (depends on 16)

The polymer sealed in-mold decoration of claim 16, wherein said substrate and said overmold are polymerized together.

### Claim 20 (depends on 16)

The polymer sealed in-mold decoration of claim 16, wherein said substrate, said in-mold decoration, and said overmold are polymerized together to form a single seamless unitary part.