Multiple applique process for injection molding articles

#The present invention relates to injection molding and more particularly to a process for injection molding contoured articles having multiple appliques.

#Currently many injection molded articles include appliques—colored and/or textured layers covering the articles for decorative or functional purposes. For example, in the automotive industry, interior trim and instrument panel controls include colored appliques to enhance the appearance of the automobile's interior.

#Appliques typically include a finished surface to provide an aesthetic appearance, for example a wood grain, and an unfinished surface to provide an interface for bonding a structural resin to the applique.

#FIG. 1 is a section view of an injection molding process of the prior art;

#FIG. 2 is a section view of a defective injection molded panel of the prior art;

#FIG. 3 is a section view of a panel molded with the process of the present invention;

#In the preferred embodiment, the present invention is described in connection with the manufacture of thermoplastic interior trim panels for automobiles. With reference to FIG. 3, a portion of panel 10 manufactured according to the process of the present invention includes appliques 20 and 30 bonded to resin layer 40. Finished surface 21 at terminating end 25 of applique 20 abuts edge 36 of applique 30. Preferably, the appliques 20 and 30 abut one another in a substantially perpendicular configuration. As used herein, “abut” and its various forms, means positioning one material in contact with, against, adjacent to, or proximate to a portion of an edge or cross section of a second material. Preferably, the edge is located at a terminating end of that second material. As used herein, “applique” means any colored and/or textured, multi layered construction associated with articles for decorative or functional purposes.

#The appliques 20 and 30 used in the present invention are preferably of different colors, patterns, and/or textures. For example, applique 20 may be colored like a wood veneer and applique 30 may be a black matte finish. Multiple appliques may be joined together in a single panel according to the present invention. Preferably, the appliques are joined in a groove, or channel, C as depicted to minimize the perceivable adjoinment of the appliques. The appliques may be joined at any corner where one terminating end may be abutted against the edge of another applique.

#With reference to FIG. 3, the appliques 20 and 30 are preferably rounded at corners R to form sidewalls 52 and 54 of channel C. Sidewalls 52, 54 of are depth D that is greater than the radius of each of the corners R so that terminating end 36 does not disengage from abutting position with respect to terminating end 25 in injection molding process.