In-mold decorating consumer electronic appliances

The in-mold decorating process begins with a decorated plastic sheet or film called an 'insert.' The decorated insert can be a flat overlay or a formed part that is die cut to fit the mold. The injection molding process begins after a decorated insert is placed in the mold, bonding the surface of the insert to the molding resin and forming a finished integral part. The result is a durable product that won't chip, scratch, or peel off because it is an integral component of the plastic injection molded assembly.

Inclosia's EXO technology is an innovative overmolding system that combines in-mold-lamination and two-shot injection molding. This enables Dow Chemicals' Inclosia to build highly differentiated eye-catching enclosures. It incorporates fur, leather, various fabrics, and even wood and metal into the surface of casings.

These are used in portable electronic devices such as cell phones, laptops, computers, and pocket calculators. The overmolding system provides the tactile and visual appeal of fabric and other materials without complex handwork or costly manual applications.

The family of EXO system solutions developed by Inclosia is designed for high-volume production of a wide range of enclosures. A variant of two-shot overmolding allows virtually any type of material to be incorporated in a covering while meeting cost, quality, durability, and volume requirements critical for the production of electronic devices.

The process starts with placing a pre-cut decorative insert into an injection mold.
 

• Once molding starts, the first shot covers the insert with a thermoplastic substrate. This also forms the enclosure's structure as required by the application.
• An optional second shot can be used to encapsulate the edges of the back molded material.

The overmolded material is permanently bonded to the outside of the enclosure. So that there are no issues with frayed edges compromising the integrity of the internal components. As one mold can be used for different materials/fabrics, retooling is not necessary between covering changes, which further increases speed and cost advantages.

The Tulip 'E-Go,' the world's first line of mass-produced leather and fabric-covered laptop computers, will be a premium quality product that distinguishes itself by its contemporary design and unique organic styling. Recently commercialized by Tulip Distribution International Holding, owner of Tulip-branded products, and Inclosia Solutions, the E-Go uses Inclosia's patented mass-production EXO overmolding system technology. Six fabric and leather laptop versions of the E-Go lifestyle laptop have been previewed at the CeBIT show in Hannover.
 

One of the newest solutions for applying textiles to rigid plastic substrates transforms the textile into an in-mold decorating (IMD) insert for use in any standard IMD process. FiberLok has developed a process for attaching tiny precolored nylon fibers perpendicularly to standard films used by injection molders for IMD.

The company's LextraFilm IMD fiber graphic products are sold in sheets or rolls to molders, OEMs, and decorative trim suppliers. The sheets of LextraFilm IMD are thermoformed, diecut, and placed in the mold before injection. Unlike the EXO process, which is performed only by Inclosia's manufacturing network, or the IMCmore, which is a major capital investment for an automotive electronic appliance application, this is a process any IMD-capable molder, custom or captive, can perform.

The LextraFilm materials provide the look and feel of denim or other textiles. However, it can also be designed to reproduce other naturally plush surfaces, such as an Oriental rug, provide abstract geometric shapes, or give other high-tech looks. The desired artwork is supplied by the customer. FiberLok does not plan to have a 'stock' lineup.

Fiberlok uses a screen process to scan and digitize fabric or images. The nylon fibers are then applied to a variety of film backings (specified or furnished by the customer) using a direct electrostatic coating process that can employ up to six colors. In addition to the potential for a unique appearance, the LextraFilm also provides a textured surface that doesn't slip, is easy to hold, and feels soft to the touch. It never feels hot, cold, or sticky, and doesn't show fingerprints.

FiberLok sees its LextraFilm IMD as a means to help U.S. and EU OEMs and molders to 'de-commoditize' their product offerings and develop unique, imaginative, and original products and processes. Candidate applications range from handheld electronics to instrument panels.