Graphic image fusion

Abstract

An in-mold and in-line decorating method is disclosed which, using a single sheet layer, allows the placement of the highest possible quality graphics into the surface of products made from a variety of moldable thermoplastic, thermoset, and vulcanizable materials using a variety of molding processes. The methods also provide new or improved capabilities for product identification, safety, and serialized tracking.

1 . A method of decorating an extruded article comprising the steps of: providing a single layer sheet containing a printed image with a material applied over said printed image, and permanently fusing said single layer sheet into the surface of a thermoplastic polymer during an extrusion process.  
   
   
       2 . The method of  claim 1  where said single layer sheet is printed using a method selected from the group consisting of lithography, screen printing, flexography, high resolution ink-jet printing, and color or monochrome electrostatic laser printing.  
   
   
       3 . The method of  claim 1  where said single layer sheet is a precipitated silica filled microporous material.  
   
   
       4 . The method of  claim 1  where said material applied over said printed image is a coating applied using a method selected from the group consisting of lithography, screen printing, and roll coating.  
   
   
       5 . The method of  claim 1  where said thermoplastic polymer is selected from the group consisting of an of polyolefins, polyesters, polycarbonate, elastomers, polyamides, polystyrene, polyphenylene oxide, polyvinyl chloride, partially devulcanized crumb rubber, crumb rubber filled polymer, and acrylonitrile-butadiene-styrene.  
   
   
       6 . A method of decorating the top and side surfaces of a three dimensional molded product comprising the steps of: introducing a three dimensional graphically printed sheet into a mold, contacting said sheet with a polymer, and permanently fusing said sheet into the surface of said polymer during the molding process to produce a fully decorated three dimensional article.  
   
   
       7 . The method of  claim 6  where said graphic image is made three dimensional by a method selected form the group consisting of by heat welding, vacuum forming, ultrasonic welding, and coining.  
   
   
       8 . A method of in-mold decorating an article containing a raised area or areas intended for subsequent decoration using post molding decorating methods comprising the steps of: introducing a sheet having a printed image in a graphic decorated area, with a material applied over said printed image into a mold, contacting said sheet with a polymer, and permanently fusing said sheet into the surface of said polymer during the molding process to produce an article having a raised area within the graphic decorated area.  
   
   
       9 . The method of  claim 8  where said subsequent post mold decorating method is selected from the group consisting of pad printing, heat transfer, foil transfer, screen printing, airbrush, and application of an adhesive label.  
   
   
       10 . A method of in-mold decorating an article comprising the steps of: introducing a single layer sheet containing a printed image with a material applied over said printed image into a mold, contacting said sheet with a thermosetting or vulcanizable material, and permanently fusing said sheet into the surface of said thermosetting or vulcanizable material during a thermosetting or vulcanization molding process to produce an in-mold decorated article.  
   
   
       11 . The method of  claim 10  where said single layer sheet is printed using a method selected from the group consisting of lithography, screen printing, flexography, high resolution ink-jet printing, and color or monochrome electrostatic laser printing.  
   
   
       12 . The method of  claim 10  where said single layer sheet is a precipitated silica filled microporous material.  
   
   
       13 . The method of  claim 10  where said material applied over said printed image is a coating applied using a method selected from the group consisting of lithography, screen printing, and roll coating.  
   
   
       14 . The method of  claim 10  where said thermosetting material is selected from thermosetting plastic or unvulcanized rubber.  
   
   
       15 . A method of decorating an extruded article during its manufacture comprising the steps of: placing a single layer sheet containing a printed image with a material applied over said printed image into the surface of a material selected from thermosetting materials or vulcanizable materials and permanently fusing said single layer sheet to said thermosetting or vulcanizable material.  
   
   
       16 . The method of  claim 15  where said single layer sheet is printed using a method selected from the group consisting of lithography, screen printing, flexography, high resolution inkjet printing, and color or monochrome electrostatic laser printing.  
   
   
       17 . The method of  claim 15  said single layer sheet is a precipitated silica filled microporous material.  
   
   
       18 . The method of  claim 15  where said material applied over said printed image is a coating applied using a method selected from the group consisting of lithography, screen printing, and roll coating.  
   
   
       19 . The method of  claim 15  where said thermosetting material is selected from thermosetting plastic or unvulcanized rubber.  
   
   
       20 . A method of in-mold decorating an article molded from a transparent polymer with a different image on the opposing surfaces of a single layer sheet comprising the steps of: introducing a single layer sheet having a first printed image on one surface with a material applied over said first printed image and having a second printed image on the opposing surface of said sheet into a mold, contacting said sheet with a transparent polymer, and permanently fusing said sheet into the surface of said polymer during the molding process to produce an in-mold decorated article having one image on its top surface and a different image visible through said transparent polymer on its bottom surface.  
   
   
       21 . A method of treating via overcoating the surface of single layer sheet containing a printed image such that said printed sheet remains dimensionally and positionally stable in a mold during a molding process comprising the steps of: selecting a UV curable clear coating material having a coefficient of friction greater than 0.5 and a cured gloss of greater than 55%, transferring said coating to a sheet intended for in-mold decorating using a process selected from the group consisting of screen printing and roll coating, and curing said coating by exposure to UV energy to produce a cross linked coating.  
   
   
       22 . The method of  claim 21  where said molding process is selected from the group consisting of injection molding, blow molding, rotational molding, gas assist molding, structural foam molding, extrusion and compression molding.  
   
   
       23 . The method of  claim 21  where the mechanism for producing said positional stability is selected from the group consisting of imparting dielectric properties that permit positionally stable placement using electrostatic charging of said sheet in any position within a mold for over 30 seconds including during the molding process, imparting a coefficient of friction between said sheet and mold surface sufficient to resist the force of molding material flowing over the molding side of said sheet, imparting a surface that softens sufficiently to produce adhesion to said mold surface sufficient to resist the force of molding material flowing over the molding side of said sheet.  
   
   
       24 . The method of  claim 21  where part design demands that the decoration be placed over the gate through which the molding material enters the mold.  
   
   
       25 . A method of treating via overcoating the surface of single layer sheet containing a printed image such that an article containing said printed sheet fused into its surface during manufacture exhibits enhanced properties selected from the group containing outdoor resistance to UV induced image fading for five to ten years, resistance to image degradation from contact with petroleum based materials or solvents, and resistance to underfoot slippage of greater than a 0.6 coefficient of friction as tested under ASTM D2047 comprising of the steps of: selecting a UV curable clear coating formulated with photochromic dies, solvent resistant acylate esters, and branched polymer chains, transferring said coating to a sheet intended for in-molding using a process selected from the group consisting of screen printing and roll coating, and curing said coating by exposure to UV energy to produce a cross linked coating having the required properties.  
   
   
       26 . A method of treating via sheet scoring comprising the steps of: printing an image on a single layer sheet, contacting said sheet with a steel roll die fabricated to impart a scored interlocking pattern, coating said sheet with a flexible coating having a tensile elongation of at least 150%, and die cutting said sheet to produce a label for in-molding on a flexible material where said image can flex and recover to original dimensions without permanent image distortion.  
   
   
       27 . A method of decorating an article made using recycled or regrind materials comprising the steps of: introducing a single layer sheet containing a printed image with a material applied over said printed image into a mold, contacting said sheet with a material containing non-homogeneous and varigated material derived from recycled or regrind feedstocks, and permanently fusing said sheet into the surface of said material during the molding process to produce an in-mold decorated article where the unacceptable appearance non-homogeneous and varigated visible surface of said article is hidden from view by said printed image.  
   
   
       28 . A method of permanently attaching a label comprising the steps of: introducing a single layer sheet containing a printed image with a material applied over said printed image into a mold, contacting said single layer sheet with a polymer, and permanently fusing said sheet into the surface of said polymer during the molding process to produce an article where the intended use makes it essential that said label remain attached and readable.  
   
   
       29 . The method of  claim 28  where said label has an intended use selected from the group consisting of serialized tracking, conveying safety information, providing product support or warranty information, and identification using a barcode.  
   
   
       30 . A method of in-mold decorating a molded article without modifying the mold used in said molding process comprising the steps of: introducing a single layer sheet containing a printed image with a material applied over said printed image into a mold, contacting said sheet with a polymer, and permanently fusing said sheet into the surface of said polymer during the molding process to produce an in-mold decorated article.  
   
   
       31 . A method of transferring labels for in-mold decorating comprising the steps of: placing single layer labels containing a printed image with a material applied over said printed image into a spring loaded cassette image side down, removing said labels from said cassette one at a time using a vacuum actuated robotic end of arm tool, transferring said label to a mold cavity using a robot and end of arm tool, and pinning said label to the mold using an electrostatic device attached to said end of arm tool.  
   
   
       32 . A method of using a silica filled microporous material to create a surface for attachment of sheet material where adhesives are incapable of effecting a permanent attachment to the underlying materials comprising the steps of: introducing a silica filled microporous sheet into a mold, contacting said sheet with a polymer, and permanently fusing said sheet into the surface of said polymer during to molding process to produce a molded surface capable of accepting adhesives for attachment of other materials to the molded surface.  
   
   
       33 . The method of  claim 32  where said sheet material is selected from the group consisting of films containing a pressure sensitive adhesive, adhesive reflective laminates, metallized foils, and laser etched reflective or refractive foils.  
   
   
       34 . The method of  claim 32  where method of attachment of said sheet material is selected from the group consisting of first attaching to said microporous material followed by fusing to said underlying material, first fusing to said underlying material followed by attachment of sheet material to said microporous material and fusing to said underlying material with the intent of future attachment of said sheet material.  
   
   
       35 . A method of using a silica filled microporous material to create on a first material a surface for attachment of a second dissimilar material without adhesives where said first and second materials could not normally be caused to fuse to one another comprising the steps of: introducing a silica filled microporous sheet material into a mold, contacting said sheet material with a polymer and permanently fusing said sheet material into the surface of said polymer during the molding process to produce a surface to which a second and dissimilar polymer can be fused creating a bond between dissimilar polymers.  
   
   
       36 . The method of  claim 35  where said first and second materials are selected from the groups consisting of rubber and plastic, polyolefin plastic and acrylonitrile-butadiene-styrene.  
   
   
       37 . The method of  claim 35  where said materials are used to make a shoe sole.  
   
   
       38 . A method of creating an article containing electrically conductive areas comprising of the steps of: applying an electrically conductive film material to one surface of a microporous sheet, introducing said sheet into a mold or an extrusion process, contacting said sheet with a polymer and permanently fusing said sheet into the surface of said polymer to produce an article having conductive areas.  
   
   
       39 . The method of claim where said conductive area forms a product usable in an application selected from the group consisting of electrical circuits and electromagnetic shields.  
   
   
       40 . A method of maintaining a printed sheet dimensionally and positionally stable in a mold comprising the steps of: introducing into a mold a sheet containing a printed image with a material applied over said printed image, and imparting dielectric properties that permit positionably stable placement of said sheet in said mold using electrostatic charging.