Bayer Corporation

Bayer Materialscience, LLC

Stephen G Smith

Keith Rao Heffley

Christopher Cooper

Timothy J Jacobs

Patrick J Griffin

Ronald W Williams

Diane D Dougherty

A method of preparing a molded article by means of an in-mold decoration process, is described. The method includes, providing a laminate () of a plurality of separate releasable thermoplastic labels () superposed over a carrier film (). A decoration () is applied in-line to the exposed second surface () of the labels (), thereby forming a decorated laminate (). The decorated laminate () is forwarded and indexed into a mold () such that the exposed first surface () of the carrier film () abuts at least a portion of the interior surface of the mold, and the decorated second surface () of the label () faces the interior space of the mold. Plastic material (e.g., thermoplastic material) is injected into the mold against the decorated surface of the label, thus forming a molded article. The carrier film () is then separated from the molded article. At least a portion of the surface of the molded article prepared in accordance with the present method is defined by the first surface () of at least one label. Molded articles that may be prepared according to the present method include identification cards, such as driver's licenses and animal tags (e.g., cattle tags), and lenses, such as tinted ophthalmic lenses and sunshade lenses.

Method of preparing a decorated molded article

A process for making a decorated article is described. The process entails printing, using a high temperature ink, a design on a surface of transfer paper, and transferring the design by sublimation to the surface of a clear flat substrate to obtain a decorated substrate. The thus decorated surface is then placed in a mold and thermoplastic resin is injected to form an article. The placing of the decorated substrate in the mold is such that the surface carrying the design faces the inside of the mold. An additional embodiment entails forming the decorated substrate to attain a three dimensional decorated substrate prior to placing it in the mold.

Decorated article made by film insert molding

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Bethel Park, PA, United States of America

Stephen G Smith