Method of making a molded applique product

A method of making applique products of the type made of synthetic resins and having printing thereon by a molding process to produce a three dimensional product having a shape including protruding portions or concave portions comprising the steps of:

• (1) providing a flat substrate having a minimum of 0.020 inches thickness, said substrate being made of a synthetic resin,
• (2) printing on a front surface of said substrate using a formable ink,
• (3) preparing the printed substrate for forming,
• (4) forming the printed substrate into a three dimensional shape having a front surface and a back surface,
• (5) providing a mold having a cavity including a mold surface of the same configuration as the front surface of said formed substrate,
• (6) preparing the formed substrate to have dimensions such that it fits into the mold cavity in a secure position with said front surface of said formed substrate in contact with said mold surface,
• (7) placing the formed substrate into the cavity of the mold in a secure position with said front surface of said formed substrate in contact with said mold surface and closing the mold in preparation for a molding operation, and, after the completion of steps (1) to (7),
• (8) injecting a molten resin into the cavity space located adjacent said back surface of said formed substrate at locations so the resin flows directly onto the formed substrate through a plurality of gates, said gates being constructed and arranged so that each gate does not supply molten resin to an area of the mold cavity greater than a predetermined area so as to reduce internal stress in the applique product produced,
• wherein step (4) is performed by a cold forming process to thereby reduce internal stress produced in the formed substrate,
• wherein step (6) of preparing the formed substrate is performed by die-cutting the formed substrate in a manner such that it is dimensioned to be placed into the mold with a minimal interference fit,
• wherein said flat substrate of step (1) is a clear polycarbonate and said molten resin of step (7) is made of a clear molten polycarbonate resin,
• wherein said formable ink is a high temperature ink that can withstand the stresses of the forming step as well as the heat from the injection of molten resin,
• wherein said mold surface is maintained at a temperature of 70.degree.-110.degree. F. and the molten resin temperature does not exceed 700.degree. F., and
• wherein said molten resin is injected through gates directly onto and perpendicular to the back surface of the formed substrate placed in the mold in step (7).