International Automotive Components Group North America, Inc.

Marc A Hayes

Mark Neitzke

Michael W Cass

Randy S Reed

Lee Childers

A method of forming a decorative article comprising placing a decorative cover sheet comprising an untextured skin layer, a cushion foam layer and an adhesive layer in a mold space between a front mold half and a rear mold half, placing a substrate on the rear mold half, heating a textured front mold surface and the skin layer with a first heater arrangement between the front mold half and the cover sheet, heating the cover sheet and the substrate with a second heater arrangement between the cover sheet and the rear mold half, forming the skin layer of the decorative cover sheet into contact with the textured front mold surface, forming into the skin layer a textured surface from the textured front mold surface, pressing the substrate against the adhesive layer of the decorative cover sheet, and bonding the cover sheet to the substrate with the adhesive layer.

Manufacture of an article having a decorative cover sheet overlying a substrate

A method of manufacturing decorative plastic composites having a decorative layer, a backing layer and a clear outer layer which provides exceptional 'depth of image' is disclosed. Decorative or protective appliqu&#xe9;s' having a wide range of decorative patterns may be formed by injection molding a backing layer behind and a clear outer layer on the top surface of a relatively thin foil, film, fabric, veneer or sheet of paper.

In mold lamination of decorative products

A method of manufacturing decorative plastic composites having a decorative layer, a backing layer and a clear outer layer which provides exceptional 'depth of image' is disclosed. Decorative or protective appliqu&#xe9;s' having a wide range of decorative patterns may be formed by injection molding a backing layer behind and a clear outer layer on the top surface of a decorative layer, the decorative layer comprising a relatively thin metal foil, film, fabric, veneer or sheet of paper having a digital image from an inkjet printer deposited on a front surface thereof. In one exemplary embodiment, the appearance of a wood veneer may be modified by digitally printing a burl pattern over the wood grain surface of the veneer prior to injection molding.

A method of manufacturing decorative plastic composites having a decorative layer, a backing layer and a clear outer layer which provides exceptional 'depth of image' is disclosed. Decorative or protective appliqu&#xe9;s' having a wide range of decorative patterns may be formed by injection molding a backing layer behind and a clear outer layer on the top surface of a thin foil, film, fabric or veneer. A method is also disclosed for coating the exposed surface of the decorative layer between injection of the backing and outer layers to impart a desired visual effect or repair the surface. Use of multiple layers of decorative film, clear plastic and colored/opaque plastic is also disclosed to provide distinguishing visual effects.

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Plymouth, MI, United States of America

Marc A Hayes