Method of making a plural component show face trim part and parts made thereby

Abstract

A method for insert-molding a plural color film laminate part and part made by the method. The method comprises preforming a film laminate and subsequently insert-molding a plastic substrate against the preformed film laminate. An improvement in traditional insert molding techniques is provided by use of a specific mold cavity structure which facilitates positioning of the film laminate transition line(s) between colors within longitudinally extending groove(s) in the part show face. According to one embodiment, the film laminate is preformed with a re-entrant edge portion which is positioned within the mold cavity such that the edge of the plastic substrate will be substantially covered. The insert molding step involves positioning the preformed film laminate in a specially configured mold cavity, closing the mold and injecting molten resin into the mold cavity against the film laminate. The part includes a show surface having the paint film laminate superposed over a portion of the underlying substrate with a portion of the substrate exposed to provide a plural color or plural component aesthetic effect. The boundary between the paint film laminate and substrate, on the show surface, is defined by a channel into which an edge of the film laminate is tucked.

1 . Plastic part comprising a show surface having a paint film superposed over a portion of said show surface thereby revealing an exposed portion of said substrate on said show surface, a boundary between said paint film and said exposed portion of said substrate, said boundary defining a channel formed in said show surface, said paint film including a first edge portion thereof disposed in said channel and hidden from said show surface.  
   
   
       2 . Plastic part as recited in  claim 1  further comprising a rope-like member disposed in said channel adjacent said first edge portion of said paint film.  
   
   
       3 . Plastic part as recited in  claim 1 , wherein said paint film comprises a pair of opposed edge portions, and said boundary defines a pair of channels formed in said show surface, each of said opposed edge portions of said paint film being disposed in one of said channels with each of said opposed edge portions being hidden from said show surface.  
   
   
       4 . Plastic part as recited in  claim 3  further comprising first and second rope-like members, said first rope-like member disposed in one of said channels adjacent one of said edge portions of said pair of opposed edge portions, said second rope like member disposed in the other of said channels adjacent the other of said edge portions.  
   
   
       5 . Plastic part as recited in  claim 3 , wherein said paint film comprises a third edge portion connecting said pair of opposed edge portions, said boundary further comprising a third channel formed in said show surface and connecting said pair of channels thereby forming a continuous recess in said show surface, said third edge portion of said paint film disposed in said third channel and hidden from said show surface.  
   
   
       6 . Plastic part as recited in  claim 1 , wherein said paint film comprises a second edge portion, said substrate comprising a longitudinally extending edge portion, said second edge portion of said paint film covering said longitudinally extending edge portion of said substrate.  
   
   
       7 . Plastic part as recited in  claim 1  wherein said channel comprises an outboard wall and an inboard wall converging at a vertex and defining a generally V-cross sectioned channel shape, said first edge of said paint film extending along said inboard wall, covering said vertex and terminating along said outboard wall.  
   
   
       8 . Plastic part as recited in  claim 1  wherein said channel comprises an outboard wall and an inboard wall interconnected by a connecting leg wall having a radius configuration to define a generally U-cross-sectioned channel shape, said first edge of said paint film extending along said inboard edge, through said connecting leg wall and terminating along said outboard leg.  
   
   
       9 . Plastic part as recited in  claim 1  wherein said channel comprises an outboard wall and an inboard wall, a connecting wall interconnecting said outboard wall and said inboard wall at a substantially normal angle, said first edge of said paint film extending along said inboard edge, through said connecting wall and terminating along said outboard wall.  
   
   
       10 . Plastic part as recited in  claim 1  wherein said channel comprises an outboard wall and an inboard wall, a connecting leg wall interconnecting said outboard wall and said inboard wall at the nadir of said channel, said first end extending along said inboard wall and embedded in said plastic below said channel nadir.  
   
   
       11 . Plastic part as recited in  claim 1  wherein said channel comprises an outboard wall and an inboard wall, a connecting wall interconnecting said outboard and inboard wall, said film extending along said inboard wall and said first edge of said paint film being contiguous with said connecting wall.  
   
   
       12 . Plastic part as recited in  claim 1  wherein said channel comprises an outboard wall and an inboard wall, a connecting wall interconnecting said outboard wall and said inboard wall and wherein said channel comprises a longitudinal axis and a nadir disposed along said interconnecting wall, said paint film extending along said inboard wall, in contiguous relation to said nadir and extending along a linear tangent generally parallel to said nadir and at a substantially normal angle to said longitudinal axis of said channel.  
   
   
       13 . A plural component show face trim part, comprising: 
 a plastic substrate including first and second side portions defining first and second edges, said substrate having a pair of grooves between said first and second edges;    a film having a pair of end portions; and    said film being fused to said plastic substrate with each one of said end portions disposed individually within one of said grooves.