Hybrid pigmented hot stitched color liner system

1. A method of making a liner for an appliance, the method comprising:

mixing a polymeric capping layer precursor and a pigment additive to form a color capping layer such that a pigment concentration in the color capping layer is at least about 10% by weight;

extruding a polymeric base resin to form a polymeric base layer at a base layer formation temperature, wherein the polymeric base layer comprises from about 1% to about 30% of the pigment additive by weight; and

laminating the polymeric base layer and the color capping layer to form the liner at about the base layer formation temperature.

2. The method according to claim 1 , wherein the color capping layer and the polymeric base layer are each formed using at least one of a high-impact polystyrene (HIPS), polymethylmethacrylate (PMMS), polystyrene (PS), acrylonitrile butadiene styrene (ABS), polyurethane (PU), polypropylene (PP), polyethylene (PE), or a combination thereof.

3. The method according to claim 1 , wherein the color capping layer comprises from about 70% to about 90% by weight polymeric capping layer precursor and from about 10% to about 30% pigment additive by weight.

4. The method according to claim 1 , wherein the base layer formation temperature is from about 120° C. to about 160° C.

5. The method according to claim 1 , wherein the mixing step is conducted with an extruder and the laminating step is conducted with one or more calendaring rollers.

6. The method according to claim 1 , further comprising:

forming a textured pattern on an outer surface of the color capping layer.

7. The method according to claim 1 , wherein the mixing and the laminating steps are conducted such that the color capping layer exhibits a predetermined color.

8. The method according to claim 1 , further comprising:

shaping the liner into a final liner at a shaping temperature wherein the final liner is suitable for assembly into a refrigeration appliance.

9. The method according to claim 1 , wherein a thickness of the color capping layer is between about 0.10 mm and less than 1.0 mm.

10. The method according to claim 1 , wherein the step of laminating the polymeric base layer and the color capping layer to form the liner at about the base layer formation temperature is performed as a hot lamination process.

11. A method of making a liner for an appliance, the method comprising:

mixing a polymeric capping layer precursor and a pigment additive to form a color capping layer such that a pigment concentration in the color capping layer is at least about 10% by weight, wherein a thickness of the color capping layer is between about 0.10 mm and less than 1.0 mm;

extruding a polymeric base resin to form a polymeric base layer at a base layer formation temperature, wherein the polymeric base layer comprises from about 1% to about 30% of the pigment additive by weight; and

laminating the polymeric base layer and the color capping layer to form the liner at about the base layer formation temperature.

12. The method according to claim 11 , wherein the color capping layer comprises from about 70% to about 90% by weight polymeric capping layer precursor and from about 10% to about 30% pigment additive by weight.

13. The method according to claim 11 , wherein the step of laminating the polymeric base layer and the color capping layer to form the liner at about the base layer formation temperature is performed as a hot lamination process.

14. The method according to claim 11 , wherein the base layer formation temperature is from about 120° C. to about 160° C.

15. A method of making a liner for an appliance, the method comprising:

mixing a polymeric capping layer precursor and a pigment additive to form a color capping layer such that a pigment concentration in the color capping layer is at least about 10% by weight, wherein a thickness of the color capping layer is between about 0.10 mm and less than 1.0 mm;

extruding a polymeric base resin to form a polymeric base layer at a base layer formation temperature, wherein the polymeric base layer comprises from about 1% to about 30% of the pigment additive by weight; and

laminating the polymeric base layer and the color capping layer to form the liner at about the base layer formation temperature, wherein the laminating is performed as a hot lamination process.

16. The method according to claim 15 , wherein the color capping layer comprises from about 70% to about 90% by weight polymeric capping layer precursor and from about 10% to about 30% pigment additive by weight.

17. The method according to claim 15 , wherein the base layer formation temperature is from about 120° C. to about 160° C.