DESC:FIELD
The present disclosure relates to a process for preparing in-mold decorative products having outdoor durability.
DEFINITIONS
As used in the present disclosure, the following words and phrases are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used to indicate otherwise.
In-mold decoration: The term “in-mold decoration” (IMD) refers to a type of plastic molding in which parts are allowed to be decorated during the molding cycle. IMD enhances manufacturing productivity, reduces overall system cost, and provides greater design flexibility.
Binder: The term “binder”, also referred to as “film forming binder” refers to film forming constituents of an ink composition, such as, film forming polymers that includes crosslinking agents, light stabilizers, levelling agents, antifoaming agents, anti-cratering agents and adhesion promoting agents.
Outdoor durability: The term “outdoor durability” refers to a product obtained by the process of the present disclosure having resistance to sunlight, acid, and alkali.
Pre-preg: The term refers to pre-impregnated composite fibers where a thermoset polymer matrix material, such as epoxy, is already present. Pre-pregs also refers to composite material in which a reinforcement fiber is pre-impregnated with a thermoplastic or thermoset resin matrix in a certain ratio. Pre-pregs have unique properties as they are cured under high temperatures and pressures.
Mar resistance: The term “mar resistance” refers to a surface property, whereas scratch or abrasion resistance involves the body of the material as well. Mar can be defined as a physical damage that typically occurs within a few micrometres of the surface of the topcoats
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
In-mold decoration (IMD) processes involve decorating objects as they are formed, in mold, of a heated plastic material being injected into a mold cavity. Usually a tape or strip of a decorating or protective material is automatically or manually advanced, pre-fed and positioned in the mold cavity at each molding cycle, interfacing therein with the plastic material as it is filled into the mold cavity, under heat and pressure. As the object is formed, the decorating material forms on the surface of the object and becomes an integral and permanent part of the object, through thermal transfer in the in-mold decoration process. Other molding processes, such as thermal forming, blow molding, compression molding, and stamping may also be used for the transfer of the decorative or protective material. Sometimes the process may also be called in-mold labelling or in-mold coating, and the transferable protective material may be called a thermal transfer overcoat or durable coat layer.
The decoration tape or strip usually comprises a carrier layer, a release layer, a durable layer, an ink or tie-coat layer and also a layer of decorative designs (metal or ink). After the injection molding transfer, the carrier layer and the release layer are removed, leaving the durable layer as the outmost layer. The durable layer serves as a protective layer with scratch resistance, mar or abrasion resistance and solvent resistance to protect the decorative designs and also the molded object. The ink layer is incorporated into the decoration tape or strip to provide optimum adhesion of the decoration tape or strip to the top surface of the molded object.
However, the currently available colors used for IMD for outdoor applications, such as water tanks, do not provide the adequate outdoor weatherability. Products, such as battery jackets require being resistant to strong acids, which is not available with the current battery jackets. Currently available ink systems do not have strong acid and alkaline resistance, and outdoor durability.
Therefore, there is felt a need to provide a process for preparing in-mold decorative products having outdoor durability, which overcomes the drawbacks mentioned herein above.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
Another object of the present disclosure is to provide a process for preparing in-mold decorative products having outdoor durability.
Still another object of the present disclosure is to provide a process for preparing in-mold decorative products that is acid and alkaline resistant and have outdoor durability.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure provides a process for preparing in-mold decorative products. The process comprises providing a porous carrier layer. The porous carrier layer is coated with an ink to obtain an ink coat on the porous carrier layer. The ink can be white, transparent, or opaque. An ink composition/colored ink layer is printed on the coat on the porous carrier layer to obtain a colored coat. The overcoat varnish is applied to the colored coat followed by forming an adhesive layer having a release liner on to the overcoat varnish to obtain a layered product. The layered product is subjected to molding with a substrate to obtain the in-mold decorative product. The in-mold decorative products have outdoor durability.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The in-mold decorative products of the present disclosure will now be described with the help of the accompanying drawing, in which:
FIG. 1 illustrates a process for preparing in-mold decorative products having outdoor durability in accordance with the present disclosure.
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Products prepared by conventional in-mold decorative processes do not exhibit adequate outdoor durability, and acid and alkaline resistance. The prints/images become distorted or completely peel off on prolonged exposure to acid, and/or alkaline conditions. One of the methods for increasing the life of the prints/images, include a pre-step of flaming the surface before the application of the ink. Flaming of the surface results in increased surface tension, and when the ink is applied to such a surface, increases the durability of the prints/images. However, this technique includes more steps, and also consumes more quantity of ink, and hence increases the overall operational cost. Also, flaming of the surface is not feasible for large containers, and printing is not uniform in such cases, as it is difficult to spread all the areas. Further, the prints/images fade/distort over a period of time.
The present disclosure envisages a process for obtaining in-mold decorative products having prints/images that mitigates the hereinabove mentioned drawbacks.
In an aspect of the present disclosure, there is provided a process for preparing in-mold decorative products having outdoor durability, as illustrated in Figure-1. Referring to Figure-1, the process comprises a sequential application of colored inks and varnishes on a porous carrier layer. The printing sequence is given below:
- providing a porous carrier layer;
- coating the porous carrier layer with an ink to obtain an ink coat on the porous carrier layer;
- printing an ink composition/colored ink layer on the white coat on the porous carrier layer to obtain a colored coat;
- applying a layer of overcoat varnish to the colored coat;
- forming an adhesive layer having a release liner on the overcoat varnish to obtain a layered product; and
- molding the layered product on to a substrate to obtain the in-mold decorative product.
The porous carrier layer can be synthetic thermoplastic polymer. The synthetic thermoplastic polymer can be selected from polyolefin polymer and polyvinyl chloride. In an embodiment, the polyolefin polymer is TESLIN® (synthetic polyolefin polymer) and polyvinyl chloride polymer is LINTECH® (polyvinyl chloride).
Typically, the porous carrier layer is pre-dried at a temperature in the range of 100 °C to 150 °C for a time period in the range of 2 hours to 5 hours prior to the IMD process. The porous layer is pre-dried to remove the moisture present in the layer.
In the next step, the porous carrier layer is coated with ink to obtain an ink coat on the porous carrier layer.
The ink used in coating the porous carrier layer can be white ink, transparent ink or opaque ink. In one embodiment, the ink used in coating the porous carrier layer is white ink. The white ink comprises titanium dioxide which helps in stabilizing the colored ink. In an embodiment only one coat of white ink is applied on the porous carrier layer. In another embodiment, more than one coat of white ink is applied on the porous carrier layer.
Further, an ink composition/colored ink layer is printed on the coat on the porous carrier layer to obtain a colored coat.
The colored ink/ ink composition of the present disclosure comprises at least one coloring agent, at least one pigment and ink binders.
The colouring agent may be either dissolved or dispersed in a liquid medium of the ink composition. Preferably, the colouring agent is a dispersible pigment, which is commercially available under the trade-names Paliotol (available from BASF PLC), Cinquasia, Irgalite (both available from Ciba Speciality Chemicals) and Hostaperm, Sudarshan chemicals.
The pigment may be of any desired colour such as, for example, Carbon black HAFN330 CI No 77266, Mogal L, Lemon Yellow 1240 CI No 77603, Simular Fast Yellow, Lemon Chrome CI No 77600, Middle Chrome , Cromopthal Yellow 8GN CI No 20037, Scarlet Chrome 1475 CI No 77605, Cromopthal Reb BRN CI No 20735, Cromopthal Scarlet RN CI No 20730, Sudarshan Pink 2190 CI No 73915, Fast Pink DB – CI 146, Beta Blue 2680 CI No 74160, Sudarshan Green 2724 CI-17 CI No 74260, Prime Rose Chrome 1011 CI No 77603, Hostaperm Orange GR, Printex 45, Sudarshan Yellow 162 CI – 17, Novaperm Yellow HR-1D CI No 21108, Hostaperm Violet RL021N CI No 51319, Sudaperm Orange 2915 CI-36 CI No 11780, Carmine Red BB10, Novaperm Red F5RK – IN, Novaperm Yellow HR70 CI No 211808, Bismuth Vandate 6615B, Cromopthal Yellow 8GN, Cromopthal Red BT CI No 20735, Silberline E2945, Aluminium Paste SS3500, Metal Powder company product Aluminium Paste TT 77, especially useful for trichromatic process printing. Mixtures of pigments may also be used. The pigments can be selected from the group consisting of cyan: phthalocyanine pigments such as Phthalocyanine blue 15.4, yellow: azo pigments such as Pigment yellow 120, Pigment yellow 151 and Pigment yellow 155, magenta: quinacridone pigments, such as Pigment violet 19 or mixed crystal quinacridones such as Cromophtal Jet magenta 2BC and Cinquasia RT-355D, and black: carbon black pigments such as Pigment black 7. Typically, the colouring agent can be present in an amount in the range of 20 wt% or less, preferably 10 wt% or less, more preferably 8 wt% or less and most preferably 2 wt% to 5 wt%, based on the total weight of the ink composition. Higher concentration of pigment may be used for white inks.
The ink binders can be selected from the group consisting of chlorinated polyolefins (Eastman CP 343), polyurethane, acrylics, SBR (styrene-butadiene rubber), polybutadiene, polyamides, pyrrolidone copolymers, oxazolidone copolymers, vinylidene chloride copolymers, vinyl acetate copolymers such as EVA (ethylene-vinyl acetate or vinyl alcohol copolymers), polyesters and derivatives or blends thereof, with polyurethane, acrylics or hybrids thereof as preferred. Latex ink binders or hydrocarbon dispersion inks are more preferred since they generally provide a wider process window for coating onto the durable layer of a decoration tape or strip or thermal transfer coating.
In addition to the ink binder, polymeric plasticizers can be used as additives in the ink composition. The ink layer may further comprise an inorganic particulate material selected from the group consisting of CaCO3, BaSO4, silica, glass beads, bentonite, and clay.
Typically, the ink composition has a film forming binder content of about 25-90% by weight and an organic liquid carrier content of about 10-75% by weight, preferably about 35-55% by weight binder and 45-65% by weight carrier.
Typically, the binder of the coating composition contains about 5-95% by weight of the film forming polymer. The organic carrier can contain Butyl Cellosolve Acetate, Isophorone, C-9, Methoxy propyl acetate, xylene, gamma Butryl lactone, and the like. All of the above percentages are based on the binder.
Optionally, the clear liquid medium (without pigments/colorants) can also be used that comprises an organic solvent or blend of solvents. The selection of organic solvent depends upon the requirements of the specific end use application of the ink composition of the present disclosure, such as the VOC emission requirements, the selected pigments, binder and crosslinking agents. The organic solvents can be selected from the group consisting of alcohols, such as, methanol, ethanol, n-propanol, and isopropanol; ketones, such as, acetone, butanone, pentanone, hexanone, and methyl ethyl ketone, methyl isobutyl ketone, diisobutyl ketone, methyl amyl ketone; alkyl esters of acetic, propionic, and butyric acids, such as, ethyl acetate, butyl acetate, and amyl acetate; ethers, such as, tetrahydrofuran, diethyl ether, and ethylene glycol and polyethylene glycol monoalkyl and dialkyl ethers, such as, cellosolve and carbitols; and glycols, such as, ethylene glycol and propylene glycol and mixtures thereof, and aromatic hydrocarbon solvents, such as, xylene, toluene.
The ink composition of the present disclosure further comprises an additive. The additive can improve the weatherability of the composition. The amount of the additive can be in the range of 0.1-10% by weight, based on the weight of the binder. The additive can be at least one selected from the group consisting of ultraviolet light stabilizers, screeners, quenchers and antioxidants. Ultraviolet light screeners and stabilizers can be selected from the group consisting of benzophenones, such as, hydroxy dodecyloxy benzophenone, 2,4-dihydroxy benzophenone, hydroxy benzophenones containing sulfonic acid groups and the like, benzoates, such as, dibenzoate of diphenylol propane, tertiary butyl benzoate of diphenylol propane and the like, triazines, such as, 3,5-dialkyl-4-hydroxyphenyl derivatives of triazine, sulfur containing derivatives of dialkyl-4-hydroxy phenyl triazine, hydroxy phenyl-1,3,5-triazine and the like, triazoles, such as, 2-phenyl-4-(2,2'-dihydroxy benzoyl)-triazole, substituted benzotriazoles such as hydroxy-phenyltriazole and the like, hindered amines, such as, bis(1,2,2,6,6 entamethyl-4-piperidinyl sebacate), di [4(2,2,6,6,tetramethyl piperidinyl)]sebacate and the like and any mixtures of any of the above.
In an embodiment of the present disclosure, the ink composition comprises flow control agents in an amount in the range of 0.1-5% by weight, based on the weight of the binder. The flow control agent can be selected from the group consisting of polyacrylic acid, polyalkylacrylates, polyether modified dimethyl polysiloxane copolymer and polyester modified polydimethyl siloxane.
The colored ink composition of the present disclosure can be used for all in-mold decoration processes for the manufacture of a plastic object.
Still further, a layer of overcoat varnish is applied to the colored coat followed by forming an adhesive having a release liner on to the overcoat varnish to obtain a layered product. The release liner may be applied onto the adhesive to obtain a layered product which can be then used for the IMD process of the substrate/material.
The layered product is applied on to a substrate using a molding process to obtain the in-mold decorative product.
In accordance with present disclosure the substrate can be selected from the group consisting of plastic/polymer, wood, metals, and the like. The substrate/material suitable for the object may include, but is not limited to, thermoplastic materials such as polystyrene, polyvinyl chloride, acrylics, polysulfone, polyarylester, polypropylene oxide, polyolefins, acrylonitrile-butadiene-styrene copolymers (ABS), methacrylate-acrylonitrile-butadiene-styrene copolymers (MABS), polycarbonate, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyurethanes and other thermoplastic elastomers or blends thereof, and thermoset materials such as reaction injection molding grade polyurethanes, epoxy resin, unsaturated polyesters, vinyl esters or composites, pre-pregs and blends thereof.
The material in accordance with the present disclosure may be a plastic cover of a cell phone or pager. In fact, the process as disclosed in the present disclosure is useful for any plastic objects manufactured from the in-mold decoration process, such as personal accessories, toys or educational devices, plastic cover of a personal digital assistant or e-book, credit or smart cards, identification or business cards, face of an album, watch, clock, radio or camera, dashboard in an automobile, household items, laptop computer housings and carrying cases or front control panels of any consumer electronic equipments. In one embodiment the material can be polymer/plastic used for in-mold decorative products.
The molding can be carried out by injection molding, or blow molding. In an embodiment, the IMD products are obtained by injection molding and the molding conditions are summarized in Table-1.
Table-1: Conditions for injection molding in accordance with the present disclosure.
S. No. IMD process details Parameters range
1. Barrel temperature 250 °C to 300 °C
2. Injection pressure 80 bar to 120 bar
3. Molding temperature 50 °C to 100°C
4. Speed of resin flow 40 % to 50 %
5. Molding time 20 seconds to 50 seconds
6. Total time inside the mold 30 seconds to 90 seconds

Typically, the injection molding is carried out at a temperature in the range of 280 oC to 320 oC for a time period in the range of 5 to 10 seconds, which is integrated within the system. Typically, the temperature for injection molding is 300 oC and the time period is 8 seconds.
In an exemplary embodiment, the porous carrier later is coated with the ink composition followed by at least one coat of overcoat varnish, at least one adhesive and at least one release liner. In accordance with the process of the present disclosure the release liner is removed and stick to the material which undergoes in-mold decoration. The colored inks get embedded in the porous parts of the substrate and on the material (article) permanently to obtain the in-mold decorative products. The in-mold decorative products are tested for various acid resistance test and outdoor durability tests.
In an exemplary embodiment the outdoor durable IMD decorative product is done by using TESLINE, POLYPALST IN, ink composition and POLYPLAST IN-400 adhesive.
Typically, the carrier layer/tape or strip is automatically or manually advanced, pre-fed and positioned in the mold cavity at each molding cycle, interfacing therein with the plastic material as it is filled into the mold cavity, under heat and pressure. As the object is formed, the decorating material forms on the surface of the object and becomes an integral and permanent part of the object, through thermal transfer in the in-mold decoration process. Other molding processes such as thermal forming blow molding and compression molding or stamping may also be used for the transfer of the decorating or protective material. Sometimes the process may also be called in-mold labelling or in-mold coating, and the transferable protective material may be called a thermal transfer overcoat or durable coat layer. The print/image becomes a part of the finished article itself using the process of the present disclosure. The print/image is able to withstand outdoor conditions, such as sunlight, UV radiation, corrosive environment, acidic conditions, and alkaline conditions.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.

The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/ commercial scale and the results obtained can be extrapolated to industrial scale.
EXPERIMENTAL DETAILS
Experiment-1: Preparation of in-mold decorative product in accordance with the present disclosure
An in-mold decorative product was prepared in accordance with the process of the present disclosure.
TESLIN® (porous carrier layer) was coated with white ink. After drying the white coat on the porous carrier layer, a colored ink layer was printed on the white coat. A layer of overcoat varnish comprising acrylic resin, solvent and plasticizer was applied to the obtained colored coat. An adhesive (acrylic resin) comprising a release liner is applied on the overcoat varnish and the obtained layered product was then subjected to injection molding as per the conditions mentioned below to obtain the in-mold decorative product of the present disclosure. The substrate used was polypropylene. The molding was carried out using Sumitomo SH280 injection molding machine.
S. No. Molding process details Parameter
1. Barrel temperature 280 °C
2. Injection pressure 100 bar
3. Molding temperature 85 °C
4. Speed of polypropylene resin flow 50 %
5. Molding time 30 seconds
6. Total time inside the mold 40 seconds

Experiment-2: Characterization of the in-mold decorative (IMD) product prepared in accordance with the present disclosure
The IMD product obtained in experiemnt-1 was subjected to various tests to determine its outdoor durability and resistance to corrosion. The tests carried out and the results obtained are given in Table 2:
Table 2:
S. No Test parameters Specifications Remarks
1 Petrol resistance,
100 RUB test Surface shall be free from discoloration, color fading, peeling, cracks, softened, blistering or any surface defect The IMD product prepared by the process of the present disclosure did not show any discoloration after the Petrol resistance,
100 RUB test
2 Water resistance,
48 hours immersion,
At room temperature Surface shall be free from discoloration, colour fading, peeling, cracks, softened, blistering or any surface defect The IMD product prepared by the process of the present disclosure exhibited resistance to water even after being immersed in water at room temperature for 48 hours. Also, no discoloration of the print is observed.
3 Resistance to boiling water, 30 minutes Surface shall be free from discoloration, colour fading, peeling, cracks, softened, blistering or any surface defect The IMD product prepared by the process of the present disclosure exhibited resistance to boiling water for up to 30 minutes. Also, no discoloration of the print is observed.
4 Engine oil resistance,
7 hrs immersion Surface shall be free from discoloration, colour fading, peeling, cracks, softened, blistering or any surface defect Even after immersion in engine oil for 7 hours, there is no discoloration observed in the IMD product prepared by the process of the present disclosure.
5 Heat resistance, 80± 1 °C, 1 hour Surface shall be free from discoloration, colour fading, peeling, cracks, softened, blistering or any surface defect. Heat shrinkage should not be observed in finished product The IMD product prepared by the process of the present disclosure exhibited heat resistance for up to 1 hour at 80± 1 °C.
Also, no discoloration of the print is observed.
6 Weatherometer test,
3000 hours
(800 hours result shared) Remove specimen from Weatherometer after 800 hrs testing. After removal leave the plates for 2 hours, then clean it thoroughly with IPA to remove any impurities. Shall be free from discoloration, color fading, peeling, cracks, softened adhesive, blistering.
Gloss Loss = 15% No cracks, color fading, peeling, softening and blistering is observed in the IMD product prepared by the process of the present disclosure.
7 Thermal cycling,
24 hours at 70 oC Surface shall be free from discoloration, colour fading, peeling, cracks, softened, blistering or any surface defect. Heat shrinkage should not be observed in finished product No shrinkage, cracks, color fading, peeling, softening and blistering is observed in the IMD product prepared by the process of the present disclosure.
8 Acid Resistance,
Drop test for 3 hrs at 65 oC sulphuric acid (75 gms of sulphuric acid +25 gms of water) Surface shall be free from discoloration, colour fading, peeling, cracks, softened adhesive, blistering or any surface defect. No shrinkage, cracks, color fading, discoloration, peeling, softening, blistering and surface defect is observed in the IMD product prepared by the process of the present disclosure.
9 Alkali Resistance, Immersion for 7 hours in 0.1N sodium hydroxide Surface shall be free from discoloration, colour fading, peeling, cracks, softened adhesive, blistering or any surface defect. No shrinkage, cracks, color fading, discoloration, peeling, softening, blistering and surface defect is observed in the IMD product prepared by the process of the present disclosure.
10 Cross cut adhesion test 2/25 of cut off pieces should stay in adhered condition The cut off pieces of the IMD product prepared by the process of the present disclosure remained in adhered condition.
11 Nail scratch test Surface shall be free from ink cracking, peel-off or other surface damage The IMD product prepared by the process of the present disclosure did not exhibit ink cracking, peel off or other surface damage.

It is clearly seen from Table-2 that the IMD product prepared by the process of the present disclosure exhibits acid and alkali resistance. Further, the article exhibits strong outdoor durability.
TECHNICAL ADVANCES AND ECONOMICAL SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of, a process for obtaining in-mold decorative products having outdoor durability.
The foregoing description of the specific embodiments fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values ten percent higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
,CLAIMS:WE CLAIM:
1. A process for preparing an in-mold decorative product, said process comprising the following steps:
a. providing a porous carrier layer;
b. coating said porous carrier layer with ink to obtain an ink coat on said porous carrier layer;
c. printing a colored ink layer on said coat on said porous carrier layer to obtain a colored coat;
d. applying a layer of overcoat varnish to said colored coat;
e. forming an adhesive layer having a release liner on said overcoat varnish to obtain a layered product; and
f. molding said layered product on to a substrate to obtain said in-mold decorative product.
2. The process as claimed in claim 1, wherein said ink in step (b) is white, transparent, or opaque.
3. The process as claimed in claim 1, wherein said molding is carried out by injection molding or blow molding.
4. The process as claimed in claim 1, wherein said porous carrier layer is dried at a temperature in the range of 100 °C to 150 °C prior to said step (b).
5. The process as claimed in claim 1, wherein said molding is carried out at a temperature in the range of 280 °C to 320 °C.
6. The process as claimed in claim 1, wherein said porous carrier layer is a synthetic thermoplastic polymer.
7. The process as claimed in claim 1, wherein said porous carrier layer is polyolefin polymer and polyvinyl chloride.
8. The process as claimed in claim 1, wherein said substrate is selected from the group consisting of plastic, polymer, and metal.
9. The process as claimed in claim 1, wherein said release liner from said layered product is removed prior to said molding in step (f).