Method of forming a delamination-resistant three dimensional double curvature surface colored composite article

Abstract

In this method, a delamination resistant three dimensional double curvature surface colored composite article is made by providing a membrane with a delamination-resistant coloring coating and applying the membrane to an injection mold having mold halves, a mold parting face, mold cavity edge and a mold cavity therein for the formation of an injection molded article, and injecting molten plastic into the mold cavity in order to form a three dimensional double curvature surface composite article with the membrane bonded to the injected plastic. Alternatively, the membrane is thermoformed.

1 . A method of forming a delamination resistant three dimensional double curvature surface colored composite article, comprising the steps of: 
 1) providing a membrane with a delamination-resistant coloring coating, prepared by; 
 a) forming a membrane, said membrane having a tacky surface,  
 b) laying a fibrous material onto said tacky surface of said membrane such that portions of fibers, comprising said fibrous material, are encapsulated, below said surface of said membrane and within said membrane, and  
 c) applying an uncured thermoset coloring coating, said coloring coating having a bottom surface, said bottom surface being of a tacky nature, onto said fibrous material such that remaining portions of said fibers are encapsulated within said coating, whereby fibers encapsulated by and originating within said membrane are also partially encapsulated and terminating within said coloring coating, thus providing a delamination-resistant mechanical bond between said membrane and said coloring coating, and  
   2) applying said membrane with a delamination-resistant coloring coating to an injection mold having mold halves, a mold parting face, mold cavity edge and a mold cavity therein for the formation of an injection molded article, and    3) injecting molten plastic into said mold cavity to form a three dimensional double curvature surface composite article with said membrane bonded to the injected plastic.    
     
     
         2 . A method of forming a delamination resistant three dimensional double  2  curvature surface colored composite article, comprising the steps of: 
 1) providing a membrane with a delamination-resistant coloring coating, prepared by;    a) forming a membrane, said membrane having a tacky surface,    b) laying a fibrous material onto said tacky surface of said membrane such that portions of fibers, comprising said fibrous material, are encapsulated, below said surface of said membrane and within said membrane, and    c) applying an uncured thermoset coloring coating, said coloring coating having a bottom surface, said bottom surface being of a tacky nature, onto said fibrous material such that remaining portions of said fibers are encapsulated within said coating, whereby fibers encapsulated by and originating within said membrane are also partially encapsulated and terminating within said coloring coating, thus providing a delamination-resistant mechanical bond between said membrane and said coloring coating, and    2) subsequently, thermoforming said membrane with a delamination-resistant coloring coating into a three dimensional double curvature surface composite article.    
     
     
         3 . A method of forming a delamination resistant three dimensional double curvature surface colored composite article, comprising the steps of: 
 1) providing a membrane with a delamination-resistant coloring coating, prepared by; 
 a) forming a membrane, said membrane having a tacky surface,  
 b) laying a fibrous material onto said tacky surface of said membrane such that portions of fibers, comprising said fibrous material, are encapsulated, below said surface of said membrane and within said membrane, and  
 c) applying a thermoplastic coloring coating, said coloring coating having a bottom surface, said bottom surface being of a tacky nature, onto said fibrous material such that remaining portions of said fibers are encapsulated within said coating, whereby fibers encapsulated by and originating within said membrane are also partially encapsulated and terminating within said coloring coating, thus providing a delamination-resistant mechanical bond between said membrane and said coloring coating, and  
   2) applying said membrane with a delamination-resistant coloring coating to an injection mold having mold halves, a mold parting face, mold cavity edge and a mold cavity therein for the formation of an injection molded article, and    3) injecting molten plastic into said mold cavity to form a three dimensional double curvature surface composite article with said membrane bonded to the injected plastic.    
     
     
         4 . A method of forming a delamination resistant three dimensional double curvature surface colored composite article, comprising the steps of: 
 1) providing a membrane with a delamination-resistant coloring coating, prepared by; 
 a) forming a membrane, said membrane having a tacky surface,  
 b) laying a fibrous material onto said tacky surface of said membrane such that portions of fibers, comprising said fibrous material, are encapsulated, below said surface of said membrane and within said membrane, and  
 c) applying a thermoplastic coloring coating, said coloring coating having a bottom surface, said bottom surface being of a tacky nature, onto said fibrous material such that remaining portions of said fibers are encapsulated within said coating, whereby fibers encapsulated by and originating within said membrane are also partially encapsulated and terminating within said coloring coating, thus providing a delamination-resistant mechanical bond between said membrane and said coloring coating, and  
   2) subsequently, thermoforming said membrane with a delamination-resistant coloring coating into a three dimensional double curvature surface composite article.