Method for manufacturing a composite article having a high clari

Details Method for manufacturing a composite article having a high clari Method for manufacturing a composite article having a high clari

1996-01-05

1997-06-24

Ryan, Patrick

Stock material or miscellaneous articles

Structurally defined web or sheet

Discontinuous or differential coating, impregnation or bond

428 76, 428159, 428161, 428204, 4283188, 428394, 428397, 428690, 264274, 264115, 264113, 264 465, 411 82, 411427, B32B 900

Patent

active

056415567

ABSTRACT:
A method of manufacturing a composite article having a front face containing a visible icon, which front face may be planer or arcuate. The method includes the steps of forming a core having perforate and imperforate portions in the core thereby creating a stencil defining the icon; forming an anvil having supporting surfaces in the shape of the icon and seated in supporting contact with the stencil; and forming the front layer of the article by injection molding an opaque plastic covering the front face of the core except for the imperforate portions of the stencil defining the icon. The composite article includes a core having a front face and a rear face with perforate and imperforate portions of the core forming a stencil defining the icon. An opaque plastic layer is formed on the front face of the core and covers the stencil except for the icon portion thereof. In another embodiment of the composite article, an anvil of a light transmitting plastic is installed having supporting surfaces shaped and sized to provide supporting engagement at the rear face of the core for the imperforate portions of the stencil defining the icon. In this other embodiment, the plastic core is translucent and the opaque plastic of the front layer extends through and interlocks the core and the anvil.

REFERENCES:
patent: 2285963 (1942-06-01), Gits et al.
patent: 2831453 (1958-04-01), Hardesty
patent: 3543329 (1970-12-01), Gulette et al.
patent: 4536116 (1985-08-01), Murray
patent: 4893392 (1990-01-01), Stricker et al.
patent: 5050269 (1991-09-01), Engstrom et al.

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