WO2002020240A1

WO2002020240A1 - Pressure forming method and apparatus

Info

Publication number: WO2002020240A1
Application number: PCT/US2000/023909
Authority: WO
Inventors: Kurt F. Eschenfelder; Loren R. Johansen; Michael D. Mcelhatton; Robin J. Reis; Michael J. Ruminski; Daniel L. Dunst
Original assignee: Serigraph, Inc.
Priority date: 2000-09-01
Filing date: 2000-09-01
Publication date: 2002-03-14
Also published as: AU2001226363A1; AU2000270950A1

Abstract

A pressure forming method and apparatus for use in an injection molding machine (10) for simultaneously performing the multiple functions of forming, cutting, and molding of deep-drawn injection molded pieces. The present method and apparatus of the invention eliminates individual loading of separate multiple pieces into the mold, saving loading time, reducing cycle time, and increasing through-put. The apparatus includes a forming tool having a first part and a second part for performing a forming operation on a substrate. The apparatus further includes an injection mold having a core part and a cavity part for performing a molding operation on the substrate after it has been formed in the forming tool. The apparatus places the forming tool on unused space within the injection molding machine (10), thereby utilizing the injection molding clamping pressure to closed the forming tool and seal the pressure chamber with the substrate held therein while a pressure medium is used to from the substrate in the forming tool. The apparatus results in a process which combines the three steps of forming, cutting, and injection molding a substrate into a continuous operation performed on an injection molding machine (10).

Description

PRESSURE FORMING METHOD AND APPARATUS

Background of the Invention

The present invention relates generally to in-mold decorating methods and apparatus for manufacturing deep-drawn injection molded pieces with printing thereon, sometimes called applique products, and more particularly to a pressure forming method and apparatus for use in an injection molding machine to simultaneously perform the multiple functions of forming, cutting, and molding of deep-drawn injection molded pieces.

In-mold decorating is known in the prior art. Typically, an in-mold decorated part undergoes multiple steps in its production. For example, a substrate may be printed or decorated by applying ink thereto to provide a desired graphic, such as lettering, designs, logos, etc. The printed substrate can then be pattern-cut, e.g. by die cutting, to define the perimeter of a product, remove excess material, or provide cut-outs. The printed and pattern-cut substrate is then sent to a former, where the substrate is typically manually fed into a forming machine for forming the substrate into a product shape. The formed substrate is then typically manually fed into an injection molding machine for molding the formed part. During the injection molding process, molten resin is injected into a closed mold containing the printed and pattern-cut substrate. The mold is allowed to cool and then opened to yield an injection molded piece integral with the substrate. Further cutting of the substrate may be performed during or after the injection molding process. Various printing layers, decorative graphics, or overlays may be applied to the substrate through known printing methods to yield the final decorated injection molded product.

In the case of multiple pieces connecting to a common web or matrix sheet substrate, the pattern-cutting step also separates the pieces from the web to provide separate individual pieces which are typically individually loaded into the for ηjng> machine and merrrrjection molding machine. An example of a forming machine for producing deep-drawn formed plastic pieces is shown in U.S. Patent Nos. 5,108,530 and 5,217,563 to Niebling et al. The forming machine disclosed in these patents is used for deep-drawing decorated plastic sheets by placing the sheets into a mold, closing the mold, injecting compressed air into the mold, and opening the mold to remove the formed pieces. In this forming method, the fluid pressure medium is applied directly to the sheet material, while the sheet is molded against the protruding portions of the mold cavity. The forming is conducted at an operating temperature below the softening temperature of the sheet material and at a fluid medium pressure of more than 20 bars. The formed pieces may then be placed into an injection molding machine where resin may be injection molded onto the deep-drawn pieces.

The cost of such an operation is considerable. There are the obvious costs of performing separate forming and injection molding operations, as well as material handling costs between each operation. There are also considerable hidden costs, which exist as well. Such hidden costs include coordinating all of the separate operations involved, i.e., printing, cutting, sending the part to separate stations for forming and molding, as well as labor costs associated with the numerous manual operations included therein. Furthermore, these tasks can slow the manufacturing process by creating troublesome bottlenecks. In addition, the manual nature of these processes can raise quality concerns in the finished products.

Accordingly, a need exists for a method and apparatus which allows an injection molding operation to proceed without the need to perform the pre-injection molding steps such as forming and cutting. In other words, a need exists for a device which accepts a product in sheet or web form and combines the pre-injection molding steps into one continuous feed apparatus, which eliminates the manual labor and expense associated with manufacturing conventional in-mold decorated pieces. Further, a need exists for a multi-purpose processing apparatus which allows the steps of forming, cutting, and molding to be performed on a printed or decorated substrate simultaneously at different positions within an injection molding machine.

Summary of the Invention

Therefore, it is an object of the present invention to provide a multi-purpose processing apparatus which allows the use of an injection molding machine to perform the pre-injection molding steps of forming and cutting a sheet or web of material prior to injection molding. It is another object of the invention to provide a method and apparatus, which overcomes the drawbacks of the prior art. It is a further object of the present invention to provide a multipurpose processing apparatus which accepts a web of material and combines the pre-injection molding steps of forming and cutting into one continuous feed apparatus, which eliminates the manual labor usually associated with injection molding. Further, it is also an object of the present invention to provide a multi-purpose processing apparatus which allows the steps of forming, cutting and molding to be performed on a printed sheet or web of material simultaneously at different positions within the injection molding machine. The multi-purpose processing apparatus of the present invention allows for multiple operations to be performed within the injection molding machine, eliminating the need for a separate forming or cutting machine.

The present invention provides an improvement on our earlier invention described in U.S.

Patent Application Serial No. 09/411,292, entitled, "Multi-Purpose Processing Apparatus," the disclosure of which is incorporated herein by reference. The purpose of the earlier invention is for forming shallower parts using a two-sided, matched face, forming tool. The clamping pressure of the injection molding machine is used for closing the forming tool, and thus forming parts with the closing pressure of the forming tool. In addition, the earlier invention concentrates on producing parts with shallow draw depths and planar geometries with gentle radii.

The present invention provides the inclusion of a pressure forming apparatus on an injection molding machine for reducing the manufacturing costs associated with manufacturing deep-drawn injection molded decorated parts. The present invention utilizes a different method and apparatus for forming deep-drawn decorated parts. The present invention uses a forming tool having a forming chamber on one side and a pressure chamber on the other side, which is in communication with a pressure medium. In the present invention, forming is accomplished by injecting the pressure medium into the pressure chamber to form the part on a forming surface of a removable forming tool insert attached to the first part of the forming tool. The clamping pressure of the injection molding machine is used to contain the pressure medium in the pressure chamber. The pressure forming method and apparatus of the present invention provides the ability to produce complex three-dimensionally shaped parts with deeper draws.

In the case of multiple pieces connected to a common web or matrix sheet substrate, the present invention eliminates the individual loading of separate pieces into the mold, significantly reducing loading time and hence reducing cycle time, which in turn increases efficiency and through-put, further reducing manufacturing costs. The present invention enables the substrate to be loaded into the apparatus in a single insertion step.

The present invention provides a multi-purpose processing apparatus which is able to perform both a forming operation and an injection molding operation on an injection molding machine. The apparatus of the present invention eliminates the need for a separate forming machine and combines the distinct steps of forming, cutting and injection molding into one machine. The multi-purpose apparatus results in a process, which combines the three steps of forming, cutting and injection molding into one continuous operation performed within the injection molding machine. The apparatus allows the three steps of forming, cutting and molding to be performed simultaneously as parts are fed into the multi-purpose apparatus. It also eliminates the manual handling of the parts between steps.

The pressure forming apparatus is built into a substantially conventional injection molding machine. The forming apparatus is preferably mounted to a quick change mounting plate, but may be mounted directly to both platen surfaces of the injection molding machine. The apparatus has a first portion which performs the forming operation and a second portion which performs the cutting and molding operation.

The forming operation is typically done by pressure forming. The forming operation utilizes unused space within the injection molding machine, as well as the clamping pressure already supplied by the injection molding machine. Cutting of a substrate on the apparatus of the present invention may take place prior to forming, during forming, between forming and molding, during molding, and/or after molding. The cutting operation is optional. The apparatus may be set up to perform a cutting operation at virtually any time during the process. However, a cutting operation is preferably performed between forming and molding.

In use, the process begins with a sheet or web of printed material being fed into the multi- purpose processing apparatus by a feed system. After a portion of the sheet or web is formed, it is advanced to a cutting and/or molding operation within the injection molding machine. As the formed portion is cut and/or molded, a new portion is advanced to the forming operation and formed simultaneously with the portion being cut and/or molded. The cutting and/or molding operation can be set up to either cut the sheet or web prior to molding or as part of the molding process. The process continues, forming multiple finished parts without having to manually handle the parts between processing steps.

As stated earlier, in a conventional injection molding process for producing in-mold decorated parts, numerous steps are involved. The present invention eliminates many of the steps by allowing the sheet or web of printed material to flow directly between a forming process, a cutting process, and/or a molding process, without any manual intervention. Therefore, the typical steps required for'an in mold decorated part before the part gets to an injection molding machine, i.e., forming and cutting, are not necessary. Separate forming, cutting and injection molding operations are no longer required, as these operations are performed within the same injection molding machine.

The forming apparatus includes a forming tool having a first part on the forming chamber side and a second part on the pressure chamber side opposite the forming chamber side. Both parts of the forming tool include openings extending therethrough to provide a path for a pressure medium to be applied to the pressure chamber to form a substrate or web material on the surface of the first part. The first and second parts of the forming tool have designated surfaces that face each other for engaging the substrate or web material between the designated surfaces and forming a seal when the forming tool is closed by the clamping pressure of the injection molding machine. The closed forming tool creating a pressure chamber where a pressure medium is injected into the pressure chamber through the openings in the parts of the forming tool to force the substrate or web material against the surface of the first part in the forming chamber of the forming tool. Various other features, objects, and advantages of the invention will be made apparent to those skilled in the art from the accompanying drawings and detailed description thereof.

Brief Description of the Drawings

FIG. 1 is a top view of a substrate with printing thereon prior to forming, cutting and molding in accordance with the method and apparatus of the present invention;

FIG. 2 is a perspective view of the substrate of FIG. 1 after forming in accordance with the method and apparatus of the present invention;

FIG. 3 is a cross-sectional view of the formed substrate taken along line 3-3 of FIG. 2; FIG. 4 is a perspective view of the substrate of FIG. 2 after cutting and molding in accordance with the method and apparatus of the present invention;

FIG. 5 is a cross-sectional view of the molded substrate taken along line 5-5 of FIG. 4; FIG. 6 is a side view of an injection molding machine including a multi-purpose processing apparatus constructed according to a first embodiment of the invention;

FIG. 7 is a side view of an injection molding machine including a multi-purpose processing apparatus constructed according to a second embodiment of the invention;

FIG. 8 is a side view of the forming tool of the apparatus of FIGS. 6 and 7 in an open position prior to forming a substrate;

FIG. 8 A is a more detailed view of the forming tool of FIG. 8; FIG. 9 is a side view of the forming tool of FIG. 8 in a closed position clamping a substrate between the halves of the forming tool;

FIG. 10 is a side view of the forming tool of FIG. 9 in a closed position forming the substrate; and FIG. 11 is a side view of the forming tool of FIG. 10 in an open position releasing the formed substrate to the cutting and injection molding portions of the apparatus.

Description of the Preferred Embodiments

The present invention pertains to a multi-purpose processing apparatus mounted to an injection molding machine, shown generally in FIGS. 6 and 7. The multi-purpose processing apparatus is able to perform forming operations, cutting operations, and injection molding operations simultaneously for manufacturing in-mold decorated parts on an injection molding machine. Using the method and apparatus of the present invention eliminates the need for a separate forming machine, and eliminates the pre-injection molding steps and costs associated with using such a machine for making in-mold decorating parts.

Referring first to FIG. 6, an injection molding machine 10 is shown including a multipurpose processing apparatus 12 constructed in accordance with a first embodiment of the invention. Before modification as provided by the invention, the injection molding machine 10 is one as is known in the art, such as those manufactured by Van Dorn Demag Corporation, Cincinnati Milacron, Inc., or Engel Machinery, Inc. The injection molding machine 10 includes a movable platen 14, a stationary platen 16, a web feed system 18 for feeding a web of material through the multi-purpose processing apparatus 12, and an injection system 20 for injecting plastic resin into an injection mold as is known in the art.

The movable platen 14 includes a movable mounting plate 22 mounted to the surface of the movable platen 14. The stationary platen 16 includes a stationary mounting plate 24 mounted to the surface of the stationary platen 16 of the injection molding machine 10. The movable mounting plate 22 and stationary mounting plate 24 are a standard mounting plates for use in injection molding machines. In the embodiment shown in FIG. 6, the stationary mounting plate 24 is rectangular in shape, while the movable mounting plate 22 includes a rectangular- shaped portion 26 substantially identical to the shape of the stationary mounting plate 24, with extensions 28, 30, on each end of the rectangular-shaped portion 26 for use with the web feed system 18.

The web feed system 18 is mounted to the movable mounting plate 22, and includes a top roll mount 32 attached to the end of the top extension 28, and a bottom roll mount 34 attached to the end of the bottom extension 30 of the movable mounting plate 22 for holding a supply of printed web material in roll form. A supply reel 36 of printed or decorated material 44 in roll form, is rotatably mounted to the top roll mount 32, while an end reel 38 is rotatably mounted to the bottom roll mount 34, to collect the waste if cutting is performed on the web material 44, or to retain the formed and molded parts, still in web form, if cutting is not performed. At least two tensioning mechanisms 40, 42, of generally conventional construction are provided and positioned on the movable mounting plate 22 to feed and guide the printed web material 44 from the supply reel 36 through the multi-purpose processing apparatus 12 to the end reel 38.

The injection system 20 is used for injecting molten plastic resin into an injection mold on the injection molding machine. In the injection system 20, granular plastic material is supplied to a hopper 46 connected to a heating barrel 48 for melting the granular material into a molten resin. The heating barrel 48 includes a plasticating screw 50 inserted therein and rotated by a screw drive motor 52 which is controlled by an injection controller 54 for forcing the molten resin into the injection mold. The rotating plasticating screw 50 moves the molten resin through the heating barrel 48 and into an injection nozzle 56 at one end of the plasticating screw 50 for injecting the molten resin into the injection mold. The multi-purpose processing apparatus 12 includes a forming tool 58 for performing a forming operation and an injection mold 60 for performing a simultaneous molding operation on the printed or decorated web of material 44. The forming tool 58 and the injection mold 60 are preferably mounted to the mounting plates 22, 24 of the movable platen 14 and the stationary platen 16. Alternatively, the forming tool 58 and the injection mold 60 may be mounted directly to the platen surfaces.

The forming tool 58 is generally positioned above or upstream of the injection mold 60. The forming tool 58 includes two main parts, a first part 62 attached to the mounting plate 24 of the stationary platen 16, and a second part 64 attached to the mounting plate 22 of the movable platen 14. The movable platen 14 is controlled by a clamping mechanism 66, which moves the movable platen 14 toward and away from the stationary platen 16. The first part 62 and the second part 64 have opposing surfaces 68 and 70 for engaging the web material 44 during closing of the forming tool parts 62, 64. The surfaces 68 and 70 face each other such that when the forming mold 58 is closed, surfaces 68 and 70 substantially engage each other with the web material 118 in-between, creating a pressure chamber 72 between the parts 62, 64 as shown in FIG. 9.

The injection mold 60 is positioned below or downstream of the forming mold portion 58. The injection mold 60 includes a core part 74 attached to the mounting plate 24 of the stationary platen 16, a center plate 76 mounted to the core part 74 with ejectors for ejecting the molded substrate, and a cavity part 78 attached to the mounting plate 22 of the movable platen 14. As is known in the art of injection molding, the mold components including the forming mold components are generally constructed of steel. Generally at least one cutting operation is also performed when making deep-drawn injection molded parts. In the present invention, a cutting operation may occur prior to the forming operation, during the forming operation when the forming tool parts are opening, between the forming and molding operations, during the injection molding when the mold halves are closing or opening, and/or after the injection molding operation.

Operation of the multi-purpose apparatus 12 begins with the supply reel 36 of printed or decorated web material 44 being fed through the tensioning mechanism 40 and into the forming tool 58 for forming portions of the material for making in-mold decorated parts. After the forming operation, the printed web material is advanced further, thereby feeding the just-formed part into the injection mold 60 and a non-formed part into the forming tool 58. The just-formed part is then injection molded in the injection mold 60, as is known in the art, while the newly advanced portion of printed material in the forming tool 58 is simultaneously fomied.

In the injection molding process, the injection mold is filled with molten resin as the plasticating screw 50 moves forward, or leftward as depicted in FIG. 6, forcing molten resin into the closed mold, held closed by clamping pressure of approximately 50 to 2000 tons by the clamping mechanism 66. The molten resin is typically formed from granular plastic material, melted to between 350 and 900 degrees Fahrenheit which is forced into the mold cavity at a pressure of between 1,000 and 30,000 pounds per square inch (psi). After the cavity of the mold is full, additional plastic may be compressed into the cavity to help offset the shrinkage that typically occurs during cooling. The plastic in the mold is cooled by supplying coolant through cooling passages in the mold. During cooling, heat is drawn out of the plastic so that when the mold is opened the plastic part is completely formed into a solid piece. The cooling typically takes between 7 and 45 seconds, depending on the thickness of the part. When the molded part is cool enough to hold its shape, the mold is opened and the plastic part is ejected. The mold is closed and the cycle begins again.

FIG. 7 shows a second embodiment of an injection molding machine 80 including a multi-purpose processing apparatus 82 constructed in accordance with an alternative embodiment of the present invention. The main difference between the two embodiments is that the first embodiment, shown in FIG.6, includes a web feed system for feeding a continuous web of printed or decorated material through the multi-purpose processing apparatus, while the second embodiment includes a sheet feed system for feeding individual sheets of printed or decorated material through the multi-purpose processing apparatus. In this alternative embodiment, the sheets 86 are automatically fed into the machine 80 using an attached robot 84. The sheets 86 then automatically travel through the multi-purpose processing apparatus by or through the use of the injection molding machine's robot 84.

The injection molding machine 80 includes a movable platen 14, a stationary platen 16 and an injection system 20 for injecting plastic resin into the injection mold. The movable platen 14 and stationary platen 16 include mounting plates 22, 24 for mounting the multi-purpose processing apparatus including a forming tool 58 and an injection mold 60. A sheet of printed material 86 is positioned within the multi-purpose processing apparatus 82.

The injection system 20, like FIG. 6, includes a hopper 46 connected to a heating barrel 48 for melting granular plastic material into a molten resin. The heating barrel 48 includes a plasticating screw 50 inserted therein and rotated by a screw drive motor 52 which is controlled by an injection controller 54. The rotating plasticating screw 50 moves the molten resin through the heating barrel 48 and into an injection nozzle 56 at one end of the plasticating screw 50 for injecting the molten resin into the injection mold 60.

FIGS. 8-11 illustrate a plurality of detailed views of a forming tool 58 of the multipurpose processing apparatus 12, 82 shown in FIGS. 6 and 7, in its various stages of operation. FIG. 8 illustrates the forming tool 58 in an open position prior to insertion of a substrate to be formed. The forming tool 58 includes two main parts, a first part 62 attached to the stationary platen 16, and a second part 64 attached to the movable platen 14. The first part 62 and the second part 64 have opposing surfaces 88 and 90 for engaging a substrate during closing of the forming tool parts 62, 64. The surfaces 88 and 90 face each other such that when the forming tool parts 62, 64 are closed, surfaces 88 and 90 substantially engage each other with the substrate in-between, creating a pressure chamber 72, as shown in FIG. 9.

Each of the opposing surfaces 88, 90 include a top portion 92, 94 and a bottom portion 96, 98 for engaging the substrate during closing of the parts 62, 64. The surfaces 88, 90 face each other such that when the parts 62, 64 are closed, surfaces 92, 94 and 96, 98 substantially engage each other with the substrate in-between, creating a seal, and forming the pressure chamber 72 between the surfaces 88, 90 of the first part 62 and the second part 64, as shown in FIG. 9. The forming tool 58 further includes a plurality of openings 100 extending through the platens 16, 14, and the first part 62 and the second part 64 to the pressure chamber 72 for applying a pressure medium into the pressure chamber 72 for forming appliques and substrates in the pressure chamber 72.

Forming is typically accomplished through forming pressure utilizing a pressure medium, such as a pressurized gas or liquid. The pressure forming operation could be a cold forming operation where the printed or decorated substrate, not having been heated in any way, is inserted into the forming tool and clamping pressure is applied to seal the substrate in the pressure chamber. The pressure medium is then injected into the chamber to form the part against the forming tool. Heat forming can also be used. Heat forming utilizes heating and cooling circuits to heat the forming tool parts and/or the pressure medium. The clamping pressure necessary for a forming operation is already supplied by the clamping mechanism of an injection molding machine.

FIG. 8 A illustrates a more detailed view of the forming tool 58 and its first and second parts 62, 64 attached to the platens 16, 14. The first part 62 is separated into two different heat zones 102, 104 by a separating member 110 inserted within the first part 62 of the forming tool 58. The second part 64 is also separated into two different heat zones 106, 108 by a separating member 112 inserted within the second part 64 of the forming tool 58. At least one of the heat zones 102, 106 in each of the parts 62, 64 includes a plurality of heating coils 114 snaking through the heat zones 102, 106 in a serpentine fashion. The heating coils 114 are preferably inserted within the first heat zone 102 closest to the stationary platen 16 in the first part 62, and the first heat zone 106 closest to the movable platen 14 in the second part 64. In addition, the first part 62 includes a forming tool insert 116 removably attached to the second heating zone 104 of the first part 62 for forming the shape of the substrate or web of material. Each removable tool insert, 116 is unique to the finished part is being used to create.

Referring next to FIG. 9, the forming tool 58 is shown in a closed position with an applique or substrate 118 engaged between the surfaces 92, 94 and 96, 98 of the first part 62 and second part 64. The first part 62 and second part 64 are clamped together by the clamping mechanism 66 of the injection molding machine 10, 80 as shown in FIGS. 6 and 7. The exposed surfaces 92, 96 of the first part 62 engage a first side 120 of the substrate 118, and the exposed surfaces 94, 98 of the second part 64 engage a second 122 side of the substrate 118. A compressor or pressure source 124 is coupled to the plurality of openings 100 in the platens 14, 16 and forming tool 58 through first and second conduits 126, 128 for injecting a pressure medium into the pressure chamber 72 of the closed tool 58. A first valve 130 is positioned between the first and second conduits 126, 128 for controlling the flow of the pressure medium into the openings 100 in the first 62 and second 64 parts of the forming tool 58. A second valve 132 is positioned in the second conduit 128 for controlling the flow of the pressure medium into the opening 100 in the first part 62 of the forming tool 58, and to vent pressure from the pressure chamber 72. The pressure medium forces the substrate 118 against the surface 88 of the removable tool insert 116 of the forming tool, as shown in FIG. 10.

In FIG. 10, approximately 80 to 2000 psi of forming pressure is injected into the first conduit 126 through opening 100 on the second part 64 of the forming tool 58 for forming the applique or substrate 118 against the surface 88 of the forming tool. The first valve 130 between the first conduit 126 and the second conduit 128 is closed to allow the pressure medium to enter the pressure chamber 72. The second valve 132 on the second conduit 128 is opened to the atmosphere to allow air to vent out from the forming chamber through the valve 132.

FIG. 11 shows the forming tool 58 in an open position after the substrate 118 has been formed by the pressure medium. The substrate 118 takes the shape of the surface 88 of the forming tool insert 116. After forming, the substrate 118 may go through a cutting operation, or proceed directly to the injection mold 60 for undergoing an injection molding operation. As mentioned previously, the forming tool 58 or the injection mold 60 may include cutting means provided by cutting inserts for cutting the substrate 118 while the substrate 118 is moving from the forming operation to the molding operation in the injection molding machine.

FIGS. 1-5 illustrate the various stages of producing an in-mold decorated part. FIG. 1 shows a substantially flat substrate 134 having markings 136 of a finished product and two indexing holes 138 for properly registering the substrate 134 on the injection molding machine of the present invention. The substrate 134 is typically printed or decorated with graphics such as letters, numbers, designs or other markings by various printing methods, such as silk screen printing, offset printing, flexographic printing, painting, digital printing, as well as other methods. Typically, both the front and back surfaces of the substrate 134 can be printed or decorated. The substrate 134 is typically flat before it is placed into a forming tool or an injection mold. The substrate 134 is preferably made of a plastic material, but may be made of other materials, and is typically supplied in sheet or roll form varying in thickness from 0.005 inch to 0.06 inch. The plastic material comprising the substrate may include polypropylene, polycarbonate, acrylic, vinyl, polyester, polystyrene, acrylonitrile butadiene styrene (ABS), polyethylene and others. The substrate my comprise non-plastic materials as well, such as malleable metal, fabrics, leather, or paper-based materials.

As next shown in FIG. 2, the flat substrate 134 is placed into the forming tool of the invention and formed by a pressure medium acting on the substrate to force the substrate against the surface of the forming tool insert. In this example, the forming tool insert is in the shape of a cellular telephone cover. Therefore, the substrate 134 takes the shape of a cellular phone cover, as shown in FIG. 2. A cross-sectional view of a portion of the formed substrate 134 is shown in FIG. 3. At this point in the process, the substrate 134 may also be pattern-cut e.g. by die cutting, along cut-lines to remove excess material, provide cut-outs, and define the perimeter of the final product. In the case of multiple pieces connected to a common web or matrix sheet substrate, the pattern-cutting step separates such pieces from the web to provide separate individual pieces, which are placed or fed into an injection mold. The pattern-cut substrate will appear similar to the finished product shown in FIG. 4.

After the forming operation, FIGS. 2 and 3, the substrate 134 is then placed or fed into an injection mold for an injection molding operation. During injection molding, an additional layer of material 160 is formed on the back or front surface of the substrate 134 as shown in FIGS. 4 and 5. FIG. 5 is a cross-sectional view of the formed, cut and injection molded substrate 134. The finished product, a cellular phone cover, is just one example of what one may produce using the method and apparatus of the present invention.

While the invention has been described with reference to preferred embodiments, those skilled in the art will appreciate that certain substitutions, alterations, and omissions may be made without departing from the spirit of the invention. Accordingly, the foregoing description is meant to be exemplary only and should not limit the scope of the invention set forth in the following claims.

Claims

ClaimsWhat is claimed is:

1. In an in-mold decorating method comprising: providing a substrate; decorating said substrate; providing a forming tool on a multi-purpose processing apparatus; placing said substrate into said forming tool; closing said forming tool; injecting a pressure medium into said closed forming tool to form said substrate; providing an inj ection mold on the multi-purpose processing apparatus; placing said substrate into said injection mold; closing said injection mold; injecting molten resin into said closed injection mold, cooling said injection mold, and opening said injection mold to yield an injection molded piece integral with said substrate.

2. The method according to claim 1 further comprising cutting said substrate between said forming step and said injection molding step.

3. The method according to claim 1 further comprising cutting said substrate before said forming step.

4. The method according to claim 1 further comprising cutting said substrate during said forming step.

5. The method according to claim 1 further comprising cutting said substrate during said injection molding step.

6. The method according to claim 1 further comprising cutting said substrate after said injection molding step.

7. The method according to claim 1 wherein the forming tool includes a first part mounted to a stationary platen and a second part mounted to a movable platen.

8. The method according to claim 1 wherein the forming tool includes a pressure chamber and a one-sided forming tool insert.

9. The method according to claim 8 wherein the forming tool insert is removable.

10. The method according to claim 8 wherein the forming tool includes at least one opening extending therethrough for allowing the pressure medium to be injected into the pressure chamber.

11. The method according to claim 1 wherein the forming tool includes heating coils extending through a portion of the mold halves.

12. An in-mold decorating method comprising:

decorating a substrate by applying printing or graphics thereto;

closing a forming tool around the decorated substrate; injecting a pressure medium into the closed forming tool to form the decorated substrate; placing the decorated and formed substrate into an injection mold; closing the injection mold; injecting molten resin into the closed injection mold; and cooling the injection mold and opening the injection mold to yield an injection molded piece integral with the decorated and formed substrate.

13. The method according to claim 12 further comprising cutting the substrate between the forming step and the injection molding step.

14. The method according to claim 12 wherein the forming tool, the pressure medium, and the injection mold are all part of a multi-purpose processing apparatus.

15. The method according to claim 14 wherein the multi-purpose processing apparatus is an injection molding machine.

16. The method according to claim 14 wherein the substrate automatically travels through the multi-purpose processing apparatus through the use of a robot.

17. The method according to claim 12 wherein the substrate is placed into the forming tool and placed into the injection mold by a robot.

18. The method according to claim 12 wherein the forming tool includes a first part and a second part with opposing surfaces that come in contact with each other when the forming tool closes, the surfaces substantially engage the substrate creating a seal and defining a pressure chamber between the first and second parts.

19. The method according to claim 12 wherein the forming tool includes at least one opening extending therethrough for allowing the pressure medium to be injected into the pressure chamber.

20. A multi-purpose processing apparatus, comprising: a forming portion, capable of performing a forming operation on a substrate, the forming portion mounted in an injection molding machine; a cutting portion, capable of performing a cutting operation on the substrate, the cutting portion mounted in the injection molding machine; an injection portion, capable of performing an injection molding operation on the substrate, the injection portion mounted in the injection molding machine; and a feed system for moving the substrate to be processed from one portion to another.

21. The apparatus of claim 20 wherein the forming operation, cutting operation and injection molding operation are accomplished on different parts of the substrate substantially simultaneously.

22. The apparatus of claim 20 wherein the forming portion is positioned ahead of the cutting and injection molding portions, such that the forming operation is performed on the substrate before the cutting operation and the injection molding operation.

23. The apparatus of claim 20 wherein the feed system advances the substrate from the forming portion to the cutting portion, and to the injection portion.

24. A multi-purpose processing apparatus, comprising: a forming portion, capable of performing a forming operation on a continuous web of material, the forming portion mounted in an injection molding machine; an injection portion, capable of performing an injection molding operation on the continuous web of material, the injection portion mounted in the injection molding machine; and a web feed system for moving the continuous web of material to be processed from one portion to another.

25. The apparatus of claim 24 further comprising a cutting portion, capable of performing a cutting operation on the continuous web of material, the cutting portion mounted in the injection molding machine.

26. The apparatus of claim 24 further comprising a set of quick change mounting plates, to which the forming portion and injection molding portion are removably mounted.

27. The apparatus of claim 25 wherein the forming portion, cutting portion, and injection molding portion operate substantially simultaneously on different sections of the web.

28. The apparatus of claim 24 wherein the forming portion is positioned ahead of the injection molding portion, such that the forming operation is performed on the web before the injection molding operation.

29. The apparatus of claim 24 wherein the feed system includes at least one tensioning mechanism.

30. The apparatus of claim 24 wherein the feed system includes at least one roll mount depending therefrom.

31. A method of forming, cutting, and injection molding a decorated substrate using a multi-purpose processing apparatus, the method comprising the steps of: forming a first portion of the substrate in a forming portion mounted on an injection molding machine; advancing the substrate through the multi-purpose processing apparatus; injection molding the first portion of the substrate while simultaneously cutting the first portion of the substrate within the injection molding machine; and forming a second portion of the substrate within the injection molding machine while simultaneously cutting and injection molding the first portion of the substrate.

32. The method as recited in claim 31 further comprising the step of cutting the first portion of the substrate in a cutting portion within the injection molding machine, substantially simultaneously with the forming and injection molding steps.

33. The method as defined by claim 31 wherein the substrate is advanced through the multi-purpose processing apparatus by an automatic feed system.