METHOD OF DECORATING CONTRASTING REGIONS OF A MOLDED RESIN PANEL

METHODE DE DECORATION A ZONES CONTRASTANTES SUR PANNEAU DE RESINE MOULEE

English Abstract

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Abstract:
A method of decorating the front surface of a molded
resin panel 10 to provide a decorative material 15 in
one region 12 and a contrasting decorative coating 18 in
another region 14. A resin undercoat 17 and a clear resin
top coat 19 are provided for decorative coating 18. The
method includes securing decorative material 15 to region
12 of panel 10, masking the decorative material throughout
region 12, applying the decorative coating to the unmasked
front surface regions of the panel, and unmasking the
decorative surface material. A top coat 19 is formed
to extend over both decorative coating 18 and decorative
material 15 to protect and secure the decorative material
with the same top coating that is required for the dec-
orative coating.

Claims

Claims:
1. A method of decorating contrasting regions of
the front surface of a molded resin panel with a dec-
orative material in one region of said front surface
and a decorative coating in another region of said
front surface, said decorative coating having a resin
undercoating and a clear resin top coating, and said
method comprising:
a. securing said decorative material to said one region
to form a surface decoration differing from the appearance
of said molded resin of said front surface of said panel;
b. masking said decorative material throughout said one
region of said front surface;
c. applying said decorative coating to unmasked front
surface regions of said panel outside said one region
bearing said decorative material, so said decorative
coating covers said other region of said front surface of
said panel;
d. unmasking said decorative material; and
e. forming said top coating to extend over all of said
front surface of said panel to cover both said decorative
coating and said decorative material.
2. The method of claim 1 including applying said dec-
orative material to said one region before undercoating
and forming said undercoating of clear resin extending
over said decorative material before said masking step.

Description

j r
ethod of dec~rating contras~ing
reg ons of a molded resin panel
~ack~
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For dashbQards, doors9 and elsewhere, the automo-
tive industry demands resin panels having ¢ontrasting
decorations in different reyions. A typical panel for
automotive purposes has a bright metal border and a
co~trasting region surfaced with a wood grain, printed
patte~n, simulated suede, or other decoration. Variations
on ~his can include stripes, several contrasting decors,
raised and lowered regions, recesses or ridges between
regions, and other alternatives. My invention produces
panels of this type, but is not limlted to any particular
decoration or end use.
Such panels have been made previou~ly by molding re in
to form the ba~ic panel shape, undercoating the panel with
a clear resin providing a smooth and receptive sur~ace,
vacuum metallizing this surface with a metallized layer,
covering the metal layer with a clear resin top coat, and
then adhering a contrasting applique over the top coat in
another region of the panelO The adhesive is expensive;
and the edges of the applique tend to work loose, marring
the appearance.
My invention provides more efficient methods for
de~orating molded resin panel~ and also achieves a more
attractive and durable result~ It eliminates adhesive,

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protects the edges of decorated regions~ and uses the top
coat protecting the metallized layer to also protect the
decorated surface.
Summary of the Invention
_ _
s My method decorates contrasting regions of a molded
resin panel with a decorati~7e material in one region and
a decorative coating in another region, and the decorative
coating has a resin undercoating and a clear resin top
coating. I apply the decorative material to one region
of the panel before applying the top coating over the
decorative coating, and I form the top coating to extend
over both the decora~ive coating and the decorative mater-
ial to protect and secure the material with the same top
coating that is required or the decorative coating.
Thus, accord;ng to the invention ther~ is provided
a method of decorating contrasting regions of ~he front
surface of a molded resin panel with a decorative mater-
ial in one region of said front ~urface and a decorative
coating in another region of said front surface, said
decorative coating having a resin undercoating and a
clear resin top coating, and said method comprising:
a. securing said decorati~e material to said one region
to form a surface decoration differing from the appearance
of said molded resin of said front surface o~ said panel;
b. masking said decorative material throughout said one
region of said front surface; c, applying said decorative
coating to unmasked front surface regions oE said panel
outside said one region bearing said decorative material,
so said decorative coating covers said other region of
said front surface of said panel; d. unmasking said dec-
orative material; and e. forming said top coating to
extend over all of said front surface of said panel to
cover both said decorative coating and said decorative
material.
Drawi~gLs
_
Fiyure 1 is a schematic diagram of preferred steps
in my inven~ive method;

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Figure 2 is a plan view of an illustrative panel made
according to my invention; and
Figure 3 is a partially exploded cross-sectional view
of the panel of FIG. 2 taken along the line 3-3 thereof.
Detailed Description
By several alternative preferred steps t I decorate a
panel 10 with both a decorative material 15 in one region
12 of a base or support 11 and a contrasting coating 18 in
another region 14. The contrasting regions 12 and 14 can
be arranged at different levels, given different contours,
and used for many different decorative effects. The re-
sulting panel lO can have several contrasting regions in
many different shapes and decors. A recess 13 around
region 12 between decorated surface 15 and contrasting
region 14 is useful for a masking step described below
and also conceals any mask line, but is not required.
~ begin with an injection molded base or support ll
for panel lO, and this can be formed in different ways
with different resin-forming techniques. Base 11 has a
region 12 that is preferably generally flat to facilitate
application of decorative material lSI This can be formed
with many different patterns and materials and applied
in different ways including hot stamping of other usion
bonding, printing, silk screening, painting, or other
technique.
Decorative coat 18 is typically a metallized layer
that can be vacuum deposited or spray coated in place,
but it can also be formed of other materials to have
different appearances. Decorative coat 18 requires a
resin undercoat 17 affording a smooth and receptîve sur-
face and a protective top coat l~ formed of clear resin
material through which decorative coat 18 is visible.
Undercoat 17 is also preferably formed of clear resin
material.
Top coat l9 is required to protect the appearance of
decorative coat 18; but before top coat 19 is applied,

sur~ace 15 is applied so that top coat l9 can extend
over surface 15 for protection, improved appearance~ and
durable wear life. This uses the ~equired top coat l9
to improve the panel by protecting decorative material 15
as well as layer 18. Of co~rse~ the decorative material
must be compatible with top coat 19; but this is easily
achieved.
Decorative material 15 can be secured directly to
panel ll as shown in FIGo 3 with or without leaving spaces
forming narrow contrasting stripes 16. Then clear resin
undercoating 17 can be sprayed or flow coated over surface
15, and mask 20 can be u~ed to preven~ decorative coating
18 from encroaching on surace 15. Mask 20 is formed to
fit over surface 15 and can have its edges 21 conveniently
disposed in recess 13 to help concel the mask line. Dec-
orative coating 18 can then be sprayed or vacuum deposited
over the front suxface of panel ll without spoiling the
appearance of sueface 15. Then mask 20 can be removed
and clear top coat 19 can be spray or flow coated over
both decorative coating 18 an~ surface 15 ~or additional
protection.
A contrasting stxip 22 can be left between material
15 and decorative coating 18 where undeecoat 17 or support
11 is visible through top coat l9. ~any other decorative
alternatives are possible usin~ top coat 19 to protect
sur face 15 .