Method of molding a composite

Claim 2

A process for preparing a molded composite, comprising the steps of: (A) providing at least two cooperating mold sections having surfaces which cooperate to define a mold cavity for molding the composite; (B) positioning a layer of a surface finishing film adjacent each of the surfaces of the mold sections; (C) positioning a substrate between the mold sections and intermediate the layers of surface finishing film; (D) closing the mold sections; and (E) injecting polymeric precursors into the mold cavity between the substrate and the layers of surface finishing film so as to form a layer of polymeric precursors between apposing major surfaces of the substrate and the layers of surface finishing film, the polymeric precursors filling the mold cavity and simultaneously deforming the layers of surface finishing film to conform to the surfaces of the mold sections, the polymeric precursors reacting in situ to form a polymeric layer and simultaneously chemically bond the polymeric layer to the layers of surface finishing film.

Claim 3

The process for preparing a molded composite, according to claim 1, wherein the substrate is selected from the group consisting of low carbon steel, stainless steel, aluminum, and alloys thereof.

Claim 4

The process for preparing a molded composite, according to claim 1, wherein the polymeric precursors are those suitable for preparing polyurethanes.

Claim 5

The process for preparing a molded composite, according to claim 1, wherein the surface finishing film is selected from the group consisting of acrylic polymers and polyvinyl chloride, and copolymers and laminates thereof.

Claim 6

The process for preparing a molded composite, according to claim 1, wherein the surface finishing film has a thickness from about 3 to about 4 mils.

Claim 7

The process for preparing a molded composite, according to claim 1, wherein the surface finishing film is treated to enhance its bonding to the polymeric layer.

Claim 8

The process for preparing a molded composite, according to claim 1, wherein the substrate is treated to enhance its bonding to the polymeric layer.

Claim 9

The process for preparing a molded composite, according to claim 1, wherein at least one of the apposite surfaces of the mold has a wood grain texture to impart a simulated wood grain surface to the finished surface of the molded composite.

Claim 10

The process for preparing a molded composite, according to claim 1, further comprising the steps: (F) opening the mold sections; and (G) removing the molded composite from the mold cavity.

Claim 11

A process for preparing a molded composite, comprising the steps of: (A) providing at least two cooperating mold sections having surfaces which cooperate to define a mold cavity for molding the composite; (B) positioning a layer of a surface finishing film adjacent each of the surfaces of the mold sections; (C) conforming the layers of surface finishing film to substantially the configuration of the mold cavity surface; (D) placing a substrate into the mold cavity, intermediate the layers of surface finishing film; (E) closing the mold sections; and (F) injecting polymeric precursors into the mold cavity between the substrate and the layers of surface finishing film so as to form a layer of polymeric precursors between apposing major surfaces of the substrate and the layers of surface finishing film, the polymeric precursors filling the mold cavity and simultaneously deforming the layers of surface finishing film to conform to the surfaces of the mold sections, the polymeric precursors reacting in situ to form a polymeric layer and simultaneously chemically bond the polymeric layer to the layers of surface finishing film.

Claim 12

A process for preparing a molded composite, comprising the steps of: (A) providing at least two cooperating mold sections having surfaces which cooperate to define a mold cavity for molding the composite; (B) positioning a layer of a surface finishing film adjacent each of the surfaces of the mold sections; (C) conforming the layers of surface finishing film to substantially the configuration of the mold cavity surface; (D) placing a substrate into the mold cavity, intermediate the layers of surface finishing film; (E) closing the mold sections; and (F) injecting polymeric precursors into the mold cavity between the substrate and the layers of surface finishing film so as to form a layer of polymeric precursors between apposing major surfaces of the substrate and the layers of surface finishing film, the polymeric precursors filling the mold cavity and simultaneously deforming the layers of surface finishing film to conform to the surfaces of the mold sections, the polymeric precursors reacting in situ to form a polymeric layer and simultaneously chemically bond the polymeric layer to the layers of surface finishing film.

Claim 13

The process for preparing a molded composite, according to claim 10, wherein step C includes applying a vacuum to the mold cavity surface.

Claim 14

The process for preparing a molded composite, according to claim 10, wherein the substrate is selected from the group consisting of low carbon steel, stainless steel, aluminum, and alloys thereof.

Claim 15

The process for preparing a molded composite, according to claim 10, wherein the polymeric precursors are those suitable for preparing polyurethanes.

Claim 16

The process for preparing a molded composite, according to claim 10, wherein the surface finishing film is selected from the group consisting of acrylic polymers and polyvinyl chloride, and copolymers and multilayered laminates thereof.

Claim 17

The process for preparing a molded composite, according to claim 10, wherein the surface finishing film has a thickness from about 3 to about 4 mils.

Claim 18

The process for preparing a molded composite, according to claim 10, wherein the surface finishing film is treated to enhance its bonding to the polymeric layer.

Claim 19

The process for preparing a molded composite, according to claim 10, wherein the substrate is treated to enhance its bonding to the polymeric layer.

Claim 20

The process for preparing a molded composite, according to claim 10, wherein at least one of the apposite surfaces of the mold has a wood grain texture to impart a simulated wood grain surface to the finished surface of the molded composite.

Claim 21

The process for preparing a molded composite, according to claim 10, further comprising the steps of: (G) opening the mold sections; and (H) removing the molded composite from the mold cavity.

Claim 22

A process for preparing a formed, molded composite, comprising the steps of: (A) providing at least two cooperating mold sections having surfaces which cooperate to define a mold cavity for molding the composite; (B) positioning a substrate and a surface finishing film between the mold sections; (C) closing the mold sections; (D) injecting polymeric precursors into the mold cavity between the substrate and the surface finishing film so as to form a layer of polymeric precursors between apposing major surfaces of the substrate and the surface finishing film, the polymeric precursors filling the mold cavity and simultaneously deforming the surface finishing film to conform to a portion of the mold cavity, the polymeric precursors reacting in situ to form a polymeric layer and simultaneously chemically bond the polymeric layer to the surface finishing film; (E) opening the mold sections; (F) removing the molded composite from the mold cavity; and (G) forming the molded composite, without delaminating the polymeric layer from the substrate nor the surface finishing film from the polymeric layer.

Claim 23

A process for preparing a formed, molded composite, comprising the steps of: (A) providing at least two cooperating mold sections having surfaces which cooperate to define a mold cavity for molding the composite; (B) positioning a substrate and a surface finishing film between the mold sections; (C) closing the mold sections; (D) injecting polymeric precursors into the mold cavity between the substrate and the surface finishing film so as to form a layer of polymeric precursors between apposing major surfaces of the substrate and the surface finishing film, the polymeric precursors filling the mold cavity and simultaneously deforming the surface finishing film to conform to a portion of the mold cavity, the polymeric precursors reacting in situ to form a polymeric layer and simultaneously chemically bond the polymeric layer to the surface finishing film; (E) opening the mold sections; (F) removing the molded composite from the mold cavity; and (G) forming the molded composite, without delaminating the polymeric layer from the substrate nor the surface finishing film from the polymeric layer.

Claim 24

The process for preparing a formed, molded composite according to claim 20, wherein the substrate is selected from the group consisting of low carbon steel, stainless steel, aluminum, and alloys thereof.

Claim 25

The process for preparing a formed, molded composite according to claim 20, wherein the polymeric precursors are those suitable for preparing polyurethanes.

Claim 26

The process for preparing a formed, molded composite according to claim 20, wherein the surface finishing film is selected from the group consisting of acrylic polymers and polyvinyl chloride, and copolymers and laminates thereof.

Claim 27

The process for preparing a formed, molded composite according to claim 20, wherein the surface finishing film has a thickness from about 3 to about 4 mils.

Claim 28

The process for preparing a formed, molded composite according to claim 20, wherein the surface finishing film is treated to enhance its bonding to the polymeric layer.

Claim 29

The process for preparing a formed, molded composite according to claim 20, wherein the substrate is treated to enhance its bonding to the polymeric layer.

Claim 30

The process for preparing a formed, molded composite according to claim 20, wherein at least one of the apposite surfaces of the mold has a wood grain texture to impart a simulated wood grain surface to the finished surface of the molded composite.