DECORATIVE PRODUCTS HAVING DEPTH OF IMAGE
A method of manufacturing decorative appliqués having a decorative outer layer, a clear backing layer which provides exceptional “depth of image” and a substrate layer is provided. Decorative or protective appliqués' having a wide range of decorative patterns may be formed by injection molding a clear plastic behind the surface of a thin substantially transparent film, fabric or sheet and backing such decorative composites with a substrate layer. The presence of the clear layer behind the relatively transparent decorative layer provides enhanced depth of image to the features of the decorative layer.
1 . A decorative panel, comprising:
a decorative layer which is at least partially transparent or translucent, said decorative layer having a front side and a back side;
a substantially clear plastic backing layer having a first and a second surface, said backing layer formed against said back side of said decorative layer; wherein said decorative layer comprises one of a film, a sheet, a laminate or an open weave fabric.
2 . The decorative panel of claim 1 wherein a plastic substrate layer is formed against said second surface of said substantially clear backing layer.
3 . The decorative panel of claim 1 wherein said decorative layer is formed to the shape of the decorative panel by said substantially clear backing layer.
4 . The decorative panel of claim 1 wherein said film, sheet, laminate or open weave fabric is tinted, colored, dyed, pigmented or printed upon.
5 . The decorative panel of claim 1 wherein the composition of said substantially clear plastic backing layer and said plastic substrate layer are substantially the same.
6 . The decorative panel of claim 1 wherein said decorative layer includes patterns, metallic flakes, particles or fibers.
7 . The decorative panel of claim 1 wherein said substrate layer includes features for attachment of said panel.
8 . The decorative panel of claim 1 wherein said panel is an appliqué.
9 . A process for providing a decorative panel, comprising:
providing a mold, including a mold core and a mold cover, in an injection molding machine, said mold core and said mold cover cooperating to form a first injection volume;
positioning a decorative layer between said mold core and said mold cover and closing said mold, said decorative layer having a front side and a back side;
injecting a substantially clear plastic material against said back side of said decorative layer to form a backing layer for said decorative layer, wherein said backing layer has a second surface opposite said decorative layer;
solidifying said substantially clear backing layer and opening said mold.
10 . The process of claim 9 further including;
forming a second injection volume between said mold core and said second surface of said substantially clear backing layer;
injecting a second plastic material against said second surface of said substantially clear backing layer to form a substrate layer;
solidifying said substrate layer and opening said mold.
11 . The process of claim 9 wherein said decorative layer is preformed to the shape of the mold cover.
12 . The process of claim 9 wherein said decorative layer is formed to shape by the injection of the substantially clear plastic material against said second surface of said decorative layer.
13 . The process of claim 10 wherein said mold core and said mold cover are aligned along a lengthened shear edge to allow the subsequent injection of said second plastic material.
14 . The process of claim 10 wherein said substrate layer includes features for attachment of said panel.
15 . The process of claim 10 wherein said decorative layer backed by said backing layer is transferred to a second mold for forming said substrate layer.
16 . A process for providing a decorative panel, comprising:
providing a mold, including a mold core and a mold cover, in an injection molding machine, said mold core and said mold cover cooperating to form a first injection volume;
injecting a first plastic material into said first injection volume to form a substrate layer;
solidifying said substrate layer and opening said mold;
positioning a decorative layer between said mold cover and said substrate layer and closing said mold to form a second injection volume between said decorative layer and said substrate layer, said decorative layer having a front side and a back side;
injecting a substantially clear plastic material between said back side of said decorative layer and said substrate layer to form a backing layer for said decorative layer;
solidifying said substantially clear backing layer and opening said mold.
17 . The process of claim 16 wherein said decorative layer is preformed to the shape of the mold cover.
18 . The process of claim 16 wherein said decorative layer is formed to shape by the injection of the substantially clear plastic material against said back side of said decorative layer.
19 . The process of claim 16 wherein said mold core and said mold cover are aligned along a lengthened shear edge to allow the subsequent injection of said substantially clear plastic material.
20 . The process of claim 16 wherein said substrate layer includes features for attachment of said panel.