Multilayered injection molded interlace-like article and method for molding same

Abstract

Provided is a panel, an article including such a panel and method of its manufacture, where the panel includes a base layer having a first face and a second face, integrally sandwiched between a first exterior layer applied over the first face, and a second exterior layer applied over the second face. In addition, the bulging portions of the base layer projecting from the first face and the second face are exposed through respective openings at the first exterior layer and the second exterior layer, extending in register with said bulging portions.

Claims

1. An interlace-like panel comprising a base layer having a first face and a second face, integrally sandwiched between a first exterior layer applied over the first face, and a second exterior layer applied over the second face, wherein each of the first face and the second face comprises outwardly projecting bulging portions, the bulging portions being exposed and extending in register through respective openings at the first exterior layer and the second exterior layer, wherein the respective openings are defined between bulges formed in each of the first exterior layer and second exterior layer, such that the bulging portions of the first face and the bulges of the first exterior layer and the bulging portions of the second face and the bulges of the second exterior layer are configured to create an appearance of a three-dimensional woven panel at a first external face and second external face of the interlace-like panel respectively, wherein a plurality of apertures extend in register through the base layer, first exterior layer, and second exterior layer between the bulging portions of the base layer and the bulges of the first exterior layer and second exterior layer.

2. The interlace-like panel of claim 1, wherein the base layer is made of a first material and each of the first exterior layer and the second exterior layer is made of either same or different materials comprising adequate adherence to the first face and second face of the base layer.

3. The interlace-like panel of claim 1, wherein the first exterior layer and the second exterior layer are interconnected through ribs facilitating flow of molten material during an injection molding process.

4. The interlace-like panel of claim 3, wherein the ribs extend between bulges of the first exterior layer and the second exterior layer.

5. The interlace-like panel of claim 3, wherein the ribs are boundaries of each of the apertures formed at each of the first exterior layer and the second exterior layer.

6. The interlace-like panel of claim 5, wherein each of the plurality of apertures at the first exterior layer and the second exterior layer is defined between the ribs.

7. The interlace-like panel of claim 1, wherein the bulging portions of the base layer are disposed over the first face and the second face at a uniform orientation or at a warp and weft orientation.

8. The interlace-like panel of claim 1, wherein the first exterior layer and the second exterior layer are identical and disposed in a back to back orientation.

9. The interlace-like panel of claim 1, wherein the first exterior layer and the second exterior layer are identical and rotated about an axis normal to a plane of the panel.

10. The interlace-like panel of claim 1, wherein the apertures are rectangular.

11. The interlace-like panel of claim 2, wherein adherence takes place through injection molding.

12. The interlace-like panel of claim 1, wherein the base layer, the first exterior layer and the second exterior layer have different physical or mechanical properties.

13. The interlace-like panel of claim 1, wherein the base layer is made of a rigid material, whilst one or both of the first exterior layer and the second exterior layer is made of a resilient material imparting the panel with some flexibility.

14. An article made of or comprising at least a portion of the interlace-like panel of claim 1.

15. A method for manufacturing the interlace-like panel of claim 1, carried out in an injection molding machine configured for three layer injection, the method comprising: a. injecting the first exterior layer; b. injecting the base layer over the first exterior layer, the first face of the base layer adheres to the first exterior layer; and c. injecting the second exterior layer over the second face of the base layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In order to better understand the subject matter that is disclosed herein and to exemplify how it may be carried out in practice, embodiments will now be described, by way of non-limiting examples only, with reference to the accompanying drawings, in which:

(2) FIG. 1A is a top perspective view of an interlace panel according to an example of the present disclosure;

(3) FIG. 1B is a bottom perspective view of the panel of FIG. 1A;

(4) FIG. 1C is a schematic planar top view of the panel of FIG. 1A;

(5) FIG. 1D is a left side view of FIG. 1C;

(6) FIG. 1E is a rear side view of FIG. 1C;

(7) FIG. 2 is an example of a furniture article comprising an interlace panel according to the present disclosure;

(8) FIG. 3A is a top perspective exploded view of the panel of FIG. 1A;

(9) FIG. 3B is a rendering of FIG. 3A;

(10) FIG. 3C is a bottom perspective exploded view of the panel of FIG. 1A;

(11) FIG. 3D is an enlargement of the portion marked A in FIG. 3B;

(12) FIG. 3E is an enlargement of the portion marked B in FIG. 3B;

(13) FIG. 4A is a perspective section taken along line IV-IV in FIG. 1A;

(14) FIG. 4B is an exploded view of FIG. 4A;

(15) FIG. 5A is a perspective section taken along line V-V in FIG. 1A;

(16) FIG. 5B is an exploded view of FIG. 5A;

(17) FIG. 6A is a perspective section taken along line VI-VI in FIG. 1A;

(18) FIG. 6B is an exploded view of FIG. 6A;

(19) FIG. 7A is a perspective section taken along line VII-VII in FIG. 1A;

(20) FIG. 7B is an exploded view of FIG. 7A;

(21) FIG. 8A is a perspective section taken along line VIII-VIII in FIG. 1A;

(22) FIG. 8B is an exploded view of FIG. 8A;

(23) FIG. 9A is a schematic top view of a mold useful in the process of molding a panel according to the present disclosure;

(24) FIG. 9B is a schematic side view of FIG. 9A;

(25) FIGS. 10A to 10C schematically illustrate consecutive steps in the method for molding a panel according to the disclosure;

(26) FIGS. 11A to 11C are resultant products of each step of the molding procedure; and

(27) FIG. 12 is a table representing adhering properties of different materials, in a molding process.

DETAILED DESCRIPTION OF EMBODIMENTS

(28) Attention is first directed to FIGS. 1A to 1E of the drawings illustrating a panel portion generally designated 20, the panel resembling an interlace panel such as a wickerwork panel, and which in the present example is a flat, planar, rectangular element (as a mere example only, though any practical shape and size are configurable).

(29) The panel 20 is injection molded in a process to be discussed hereinafter in greater detail.

(30) With further reference being made also to FIGS. 2 to 8, it is appreciated that the panel 20 is a composite injected element comprised of three layers, namely a base layer 24, a first exterior layer 26 (a bottom layer in the illustrated drawings) and a second exterior layer 28 (a top layer in the illustrated drawings). The appearance is such that at the integrated position, top bulging portions 30 of the base layer 24 are alternating exposed through respective openings 32 of the first exterior layer 26, and bottom bulging portions 36 of the base layer 24 are alternatingly exposed through respective openings 38 of the second exterior layer 28. This arrangement can best be seen in the exploded views.

(31) In the illustrated example the overall thickness of the base layer 24 is greater than the thickness of each of the first exterior layer 26 and the second exterior layer 28. Also, in the illustrated example the base layer 24 is of dark color, whilst the first exterior layer 26 and the second exterior layer 28 are of light color, thus imparting the panel 20 a classic warp and weft pattern.

(32) Furthermore, it is appreciated that the base layer 24, the first exterior layer 26 and the second exterior layer 28 can have different external textures (mat, gloss, texturized, etc.), and the layers can also have different mechanical properties. For example, in case the panel is part of a solid container-like article (e.g. paper basket; not shown) the three layers 24, 26 and 28 can be made of the same material. However, in FIG. 2 there is illustrated a chair 40 fitted with a seat panel 42 and a backrest 44 both secured to the frame structure 46 of the chair 40, wherein the base layer is injected of a first material, substantially hard, whilst the first exterior layer 26 and the second exterior layer 28 are injected of more resilient materials (however injection adhereable to the base layer 24), thereby imparting the seat panel 42 and a backrest 44 with some resilience for comfort.

(33) According to a particular example, the base layer can be made of a rigid material (e.g. PPpolypropylene), whilst one or both of the first exterior layer and the second exterior layer can be made of a more resilient material such as elastomeric materials (e.g. rubber or SEBSstyrene ethylene butylene styrene), imparting the panel with some flexibility. This can render it suitable, for example, for portions of furniture (e.g. seating and/or backing of a chair, etc.).

(34) FIG. 12 of the drawings is a table comprising a partial list of different materials and representing their adhesive by molding properties.

(35) It is further noted that the panel 20 is configured with a plurality of apertures 50 (see-through openings) extending in register through the base layer 24 and sandwiching first exterior layer 26 and second exterior layer 28. The arrangement being such that each such aperture at the first exterior layer 26 and the second exterior layer 28 is defined between ribs of material 54 (best seen in FIG. 3D), said ribs 54 defining the boundaries of the openings 32, 38 and configured for flow of material during the injection molding process, so as to ensure homogenous and uniform flow of material to the solid portions 32 and 33, of the first exterior layer 26 and the second exterior layer 28, respectively.

(36) The undulating pattern of the interlacing layers, together with the apertures and openings impart the panel 20 with a true feeling of a three dimensional wickerwork panel.

(37) Turning now to FIGS. 9 to 11, reference is made to a method for manufacturing a panel 20 as disclosed hereinabove. The method, as disclosed in the annexed drawings, makes use of a revolving injection molding system, schematically represented and generally designated 70 and comprising a first section A and a second section B. The revolving injection molding system 70 comprises three molding trays designated 72, 74 and 76, each configured respectively with a male mold portion designated M and a female mold portion designated F. The molding sequence takes place as follows: a. first the mold 70 closes and material is injected into mold tray 72 for injection molding of the first exterior layer 26 (FIG. 11A); b. the mold then opens, and with the first exterior layer 26 still in mold tray 72 of section B, section A of the mold revolves at 120; c. the mold 70 closes again and the base layer 24 is injected over the first exterior layer 26 in mold tray 74 (FIG. 11B); d. the mold 70 then opens again, and section A revolves at 120 with the complex molded article now retained in section B; e. the mold closes again and the third layer, i.e. the second exterior layer 28 is now injected over the base layer 24 in mold tray 76 (FIG. 11C); f. simultaneously with step e) another base layer 24 is injected in mold tray 24 and another first exterior layer 26 is injected in mold tray 72; g. the mold then opens, section A rotates again by 120 and a complete panel 20 is extracted form mold tray 76 of the mold 70; h. steps a) to g) are repeated for injection of further panels.

(38) Whilst the disclosure above refers to a revolving (rotary) mold, the same can be obtained also using a linear displaceable injection mold, mutatis mutandis.