Abstract: The present invention thus provides a plastic part with a surface area of a semi-rigid sheet material such as metal, wood or wood-based paper product and a novel process where the sheet material edges are covered with a second plastic component that adheres both to the sheet material and to the first plastic material. A first plastic substrate component is prepared with an adhered sheet material surface area and then the edges of the sheet material are overlapped by a second molded-on, plastic edge-covering component. A preferred sheet material laminate structure is also provided with a backing layer that protects an interior adhesive layer. The second molded-on edge-covering component covers the sheet material edge to provide an aesthetically pleasing surface. This construction produces a more durable sheet material edge covering and eliminates the tendency of the sheet material to peel off the molded part during use.

Abstract: The present invention provides thin injection molded plastic articles with an attractive, surface area of at least two different materials, such as leather, fabric, wood, metal or other semi-rigid surface material. These molded articles have desired combinations of thin dimensions, aesthetics and/or durability with the true feel of the real materials. The molded plastic articles thus have a plastic substrate component with a front decorative surface having at least two decorative surface areas of layers of different first and second materials having adjacent and connecting surface areas that are generally coplanar or continuous, including at the border line where the two surface layer materials meet. Relative to the front surface, at least a portion of the first material is located on top of and overlaps at least a portion of the second.

Abstract: The present invention thus provides a fabric-laminated plastic part and a novel process where the fabric that provides the surface is pre-laminated with a support layer and supplied into a molding process where a plastic substrate component is molded. The fabric surface piece is precisely located and securely bonded by selection of a support layer plastic material having sufficient heat resistance and/or thickness to sufficiently resist melt softening and stretching during the molding process. This process and fabric laminated plastic article are especially suited for preparing thin-wall, articles that need to have precisely located, smooth fabric surface areas corresponding to discontinuities, voids or openings in the underlying molded plastic article.

Abstract: The present invention thus provides a plastic part with a surface area of a semi-rigid sheet material such as metal, wood or wood-based paper product and a novel process where the sheet material edges are covered with a second plastic component that adheres both to the sheet material and to the first plastic material. A first plastic substrate component is prepared with an adhered sheet material surface area and then the edges of the sheet material are overlapped by a second molded-on, plastic edge-covering component. A preferred sheet material laminate structure is also provided with a backing layer that protects an interior adhesive layer. The second molded-on edge-covering component covers the sheet material edge to provide an aesthetically pleasing surface. This construction produces a more durable sheet material edge covering and eliminates the tendency of the sheet material to peel off the molded part during use.