MXPA00001413A - Process and apparatus for preparing a molded article - Google Patents

Abstract

A film (50) is placed over a mold cavity (12a) and molten plastic (60, 98) deposited thereon to form a combination of a film with molten plastic thereon. The film-molten plastic combination is then formed in said mold cavity (12a) into a molded article in the shape of the mold cavity (12a).

Description

PROCESS AND APPARATUS FOR PREPARING A MOLDED ITEM BACKGROUND OF THE INVENTION According to the patent of the United States ,401,457 for PROCESS FOR FORMING A COLOR COATED ARTICLE, by Emery I. Valyi, patented March 28, 1995, provides a process for forming a coated article of color. According to the patent 57, a substantially flat film is placed on a mold cavity and deformed by a core mold half and by molten plastic which enters through a casting channel. An alternative method is to thermoform the film so that it is precisely lodged in the mold cavity, where the operation is carried out independently of the mold. The formed film insert is then transported to the mold and placed inside the cavity. This procedure is described by Ch. Fridley, Avery Dennison, in Product Finishing, April 19, 1992, and in the European patent 0,442,128 to Beyer, and in other applications. In Avery procedure involves a process of film formation that is well known and widely practiced for other uses. It is a low pressure process to form the film or sheet, in solid condition, at relatively low temperatures. This supports the entirety of various thermoforming variants, such as vacuum forming, wherein the vacuum is produced to suck the film into the cavity, or over the core, as well as the thermoforming followed by dimensioning operation. The result of this is a product whose dimensional accuracy and shape adaptation is not within the range of a high pressure forming process, such as injection molding or compression molding. Consequently, the thermoformed preform, although it is housed in the mold cavity or slides on the core, does not adapt to it completely. Therefore, when injecting or compressing plastic behind the preform, the preform will deform producing localized surface imperfections. These imperfections can be dimensionally insignificant but optically discernible and therefore can generate a product of insufficient quality for automotive finishing, for example. In addition, the cost of a separately processed film insert is relatively high, considerable scraping of cuts is generated and handling (transport, removed from stacking, insertion) becomes expensive. The procedure of the patent 57 solves the above defects; however, it is difficult to control, particularly when molding parts with large surfaces and with variable curvature in a remarkable manner. These difficulties increase when the plastic is molded under pressure at temperatures high enough to reduce the strength of the film substantially, as in the case of conventional injection molding. In applying any of the above processes to large panel-like structures, it has further been found that the injection molding process of the 57th patent and the Avery Dennison procedure mentioned above is difficult to carry out, which requires extremely expensive equipment and susceptible to producing imperfections in the interface between the film layer and the injected plastic. Accordingly, it is a principal object of the present invention to provide a process and apparatus which expediently and conveniently conforms an article molded from a molten plastic and a film insert, wherein the film is the outer layer of the film. molded article and where desirably the film has color. A further objective of the present invention is to provide a process and apparatus as mentioned above which resolves the above defects and provides a commercially feasible process and apparatus for forming a coated article with color. A further object of the present invention is to provide a process and apparatus as mentioned above which is operative under conditions that are sufficiently controllable and cost efficient to produce complex parts, particularly those of a size of main body components or passenger vehicles. The additional objects and advantages of the present invention will appear in the following.

BRIEF DESCRIPTION OF THE INVENTION In accordance with the present invention, the above objects and advantages are easily obtained. The present invention includes a process for preparing a molded article, which comprises: providing a mold cavity; place a film or white on the mold cavity; depositing molten plastic on the film to form a combination of a film with a molten plastic thereon; and subsequently forming the molten film-plastic combination in the mold cavity, in a molded article having the shape of the mold cavity, wherein the film is an outer layer of the molded article. Desirably, the film has color and is held over the mold cavity and the molten plastic is deposited on the film. In addition, preferably, the combination is formed in the shape of the mold cavity, at least in part by a mold core which compresses the combination and shapes the combination to the shape of the mold cavity. Therefore, the resulting article is desirably a color coated and molded article having the desired shape, which may be a complex shape, as defined by the shape of the mold cavity. Naturally, the mold can include other components, such as slides and elevators which are well known. The present invention also includes an apparatus for preparing a molded plastic article, which comprises: a mold cavity; means for securing a film or target, desirably a color film, on the mold cavity; means for depositing molten plastic on the film to form a combination of a film with molten plastic therein; and means for shaping the molten film-plastic combination subsequent to the molten plastic reservoir on the film in the mold cavity within the molded article having the shape of the mold cavity, wherein the film is an outer layer of the article. molded. The present invention adheres to the principle of forming the film in uniformity with the plastic supporting it, and in this way carrying out a complete conformation with no detectable defects of the exposed film surface, which can be a film of paint, and to shape the resulting molded article under closely controlled conditions of temperature and pressure distribution, in an efficient manner. The additional specific features and advantages of the present invention appear in the following.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be more fully understood from a consideration of the following drawings, in which: Figure 1 is a partially schematic view of the apparatus and process of the present invention at an early stage of preparation of the molded article; Figures 2 and 3 are partial views showing variations in the process and apparatus of the present invention; Figure 4 is a further variation of a partial view of the process and apparatus of the present invention; and Figures 5, 6, 7, and 8 show further variations of the present invention. _. . DETAILED DESCRIPTION OF THE PREFERRED MODALITIES With reference to Figures 1-3, a mold 10 consisting of a cavity half 12, having a mold cavity 12a therein, and a core half 14, are mounted on respective platens 16 and 18. The mold cavity 12a has a shape of the final molded article that is desired. At least one of the half-cavity and half-core is reciprocable in the direction of the arrow 20 from an open to a closed position, and from a closed to an open position via a driving means (not shown). An extruder / injection unit 22, having a nozzle 24, is positioned adjacent the mold 10 for coacting and coupling with a hot plastic supply medium, like a plate 26. The plate 26 is relatively reciprocable in the direction of the horizontal arrow 28 from a position adjacent to the mold cavity 12a, to a position separate from the mold cavity 12a and supplied with hot and flowable plastic by the extruder 22 and the nozzle 24. Depending on the nature of the plate 26, the extruder may be stationary or reciprocable with the plate 26. Naturally, other variations may be used in the hot plastic supply system. For example, the extruder / injection system and the hot plastic supply means can be stationary external to the press, and the mold can be transverse reciprocally relative to the extruder / injection system. Other variations can be easily contemplated. The plate 26 in Figure 1 is a hot runner having an elongated channel 30 which communicates with a multiplicity of openings 32 placed on the mold cavity 12a. Each opening can be closed by a known means, for example, by a valve means 34. The openings 32 receive hot plastic under pressure from the extruder 22 through the nozzle 24 of the extruder and a slurry feed channel 30. Although the extruder 22 and the hot runner supply plate 26 are engaged, the plastic is caused to flow from the nozzle 24 into the channel 30. For the supply plate to operate when the extruder is detached, a free end 36 of the channel 30 contains a check valve 38 (shown schematically) and a pressurized piston means 40 that is added to engage the opposite end 42 of the channel 30 to operate by a conventional means, for example, a hydraulic cylinder (not shown) for application force a hot slide channel 30 in the direction of the horizontal arrow 44. Alternatively, one can selectively close the valve means 34 and apply pressure through the piston means 40, in order to obtain a thicker coating in desired positions. Alternatively, one can use emptying containers or plastic containers, for example, connected to each individual valve, whereby additional resin thicknesses are obtained where desired. In one method of operation, the extruder 22 is on the left placed separately from the mold 10 and the plate 26 alone moves in position over the mold cavity 12a, as shown in Figure 1, after having been loaded with plastic heated by the extruder 22. To prevent spillage, the check valve 38 is closed. Furthermore, the piston means 40 can be retracted in engagement with the channel end 42, whereby suction is generated at the channel end 42 for better retain the hot plastic in it. A retention frame 26 downward and spacer, is aligned with the cavity half 12, engageable therewith and detachable therefrom and engaging with a means for moving the same (not shown) towards and away from the 12 cavity half dependent on the reciprocal movement of the core half 14. Therefore, a pair of lifting cylinders 48 can be mounted on both plates 16 or 18 with the assembly on the plate 16 shown in Figure 1. Therefore, the plate 26 is filled with hot plastic by the extruder 22. If the two are coupled, they move so as to place the hot slide in alignment with the cavity half 12. Prior to placing the hot slide in this manner, the spacer frame 46 is raised away from the cavity half 12 far enough to allow a pre-cut or white film 50 to be placed over the edge 52 (see FIG. 2) of the cavity 12a of mold of the cavity half 12 by any desired means, such as for example, that shown in the patent 57. With the blank 50 in place, the frame 46 moves towards the cavity half 12 to hermetically hold the target 50 on the mold cavity 12a, as shown in Figure 2, to thereby return to the cavity capable of retaining high fluid pressure. Optionally, the film can be deflected from the cavity and held by air jets. Alternatively, the spacer frame 46 may include an upper half 46a and a lower half 46b with a space 47 therebetween, as shown in Figure 1. A slideable fastener for allowing release of the film in the mold cavity 12a during the shaping and therefore minimize the scraping of the edge and reduce the amount of film thinning that may occur. If desired, the scraping cut can be minimized by bending the excess film and heat sealing the excess film towards the inside of the edge portions of the molded article, for example by ironing. Then fluid pressure can be applied to the mold cavity 12a below the blank 50, via the channels 54 connected through the joint manifold 56, with a pressure control means 58. The fluid usually used is air, but it can also be an inert gas if the target material 50 so requires. Alternatively, the fluid pressure can be applied through the channel 55 and the cavity half 12 directly below the film target or the film 50 in order to properly hold the film-li in place. Preferably, a plurality of positions or a continuous channel is provided around the circumference of the film directly below the film. In addition, these can be activated by valves separately from the channels 54, or they can be used instead of the channels 54. The nozzle valve means 34 is then removed to allow the hot plastic to flow freely from the hot slide plate 26 through the nozzle openings 32 on the blank 50 in the space between the hot slide plate 26 and the blank 50, and within the frame 46. The space within the frame 46 is not filled under substantial pressure, such as is customary in injection molding. Instead of this, only an accurately dosed quantity of hot plastic 60 is deposited on the blank 50 from the hot slide plate 26, specifically that in which it substantially corresponds to the molding cavity to be formed in the cavity 12a of mold in the cavity half 10 and the core half 14 in the closed condition. It is important to note that as a consequence of introducing the hot plastic into the space within the frame 46, no more pressure is applied under the target via fluid channels 54 and 55 than is sufficient to hold the dosed quantity 60 of plastic that is has deposited. Desirably, the air pressure is variable based on the requirements of the product. Actually, vacuum can be used during shaping. As schematically indicated in Figure 1, this dosed quantity 60 will comprise a plastic layer which will conform to the flat surface of the blank on one side while its opposite surface will have an irregular surface 62, as clearly shown in Figure 1, showing traces of the viscous flow pattern that will have arisen in the nozzles 32. Naturally, the nozzles are narrowly separated enough to allow the emerging plastic to form a continuous homogeneous layer. Alternatively, a polymer can be deposited in a designed pattern, and a second or a plurality of second polymers are deposited in a designed pattern. This can be done with one or more extruders that feed, for example, separate channels to deposit a previously designed pattern of multiple resins. As a further alternative, one can sequentially feed polymers of different characteristics to provide designed properties in the finished product. Each of the nozzles 32 can be controlled in terms of temperature independently, if so desired, and therefore be able to deposit the plastic in a predetermined temperature distribution pattern. Before releasing the hot plastic within the space above the blank 50, the mold cavity 12a is pressurized as described above, for example by air pressure coming through the channels 54. Since the finished product is currently thin , although it has a large surface area, the weight of the dosed plastic 60 is relatively low and the average static pressure exerted on the film or target 50 is also low. Therefore, a relatively low pressure in the mold cavity will be sufficient to maintain the target 50 preventing it from sliding under the weight of the metered plastic, even when the target 50 is heated by contact with the metered plastic. For example, a dosed amount of plastic measuring 0.61 mx 1.2 mx 13 mm (2 'x 4' x 0.5"), made of a plastic weighing 1.4 g / cm1 (0.05 pounds per cubic inch) will exert a pressure of 172 Pa (0.025 psi) over such an area This is a very light overpressure to support the target, with the result that the target will not buckle (a balloon will form) upwards excessively when the first pressure is applied below it. In exceptional cases, the hot plastic layer applied to the target may be of a much greater depth, Even then, the pressure indicated above will not cause excessive buckling.The formation of a crease-like line at the edge of frame 46 separator, it can be avoided as shown by a curved clamping surface 64 thereof in Figure 2 with a slightly upward bulging of the film 50 shown caused by pressurization of the mold cavity 12a. Upward buckling may be desirable in some cases, such as for drag-fed parts. After the deposition of the plastic layer 60 on the film 50, the plate 26 moves from between the cavity half 12 and the core half 14 and the mold 10 is closed, for example by moving the core half 14 inside. of the mold cavity 12a. This results in the shaping of the film and the plastic deposited within a composite laminate in the form of a closed mold cavity in an expeditious and convenient manner. The preform is preferably plastic, and any desired plastic material for the target or molten plastic material can be used, for example, polyolefins, polyvinyl chloride, polystyrene, polycarbonates, etc. Any thermoplastic and / or thermosetting material can be used for the molten material, such as, for example, structural foam, riiti, epoxy material, polyurethanes, volume molded compounds, sheet molded composites, etc. The blank can be cut or stamped from a web and a supply of blanks having the size and shape to be placed on the mold cavity 12a maintained adjacent the mold 10 for transfer to the mold as described above. The depth of the white color can vary naturally depending on the needs. One can naturally consider thinning the white or the film during processing and adjusting the depth of color to the amount of deformation that any portion of the blank or film will undergo. Thus, for example, coarser paint coatings can be applied to target positions or selective films that will obtain greater deformation during processing in order to obtain uniformity of color in the final molded product. The white or the film can, for example, be engraved in a hole. The white can be applied to the mold by means of robots or it can be attached removably to a strip of carrier film. The carrier film strip may be provided with a means for aligning the position of the targets in relation to the mold half on which the targets are to be placed, for example, edge perforations. The carrier, with the blanks attached, can then be supplied from a roller. Once the blank and the mold are juxtaposed, suction is applied to the edge of the blank by the mold, through channels, enough to separate the target from the carrier strip. Naturally, other transfer means can be easily used. Figure 3 shows an alternative method for applying hot plastic. Instead of the plate 26 which constitutes a hot slide as shown in Fig. 1, the extruder 22 engages with what is called a liner holding die 70, which serves as a hot plastic supply plate, i.e. a die with a groove opening 72 for the plastic as is normally used for the extrusion of broad sheets. The extruder 22 and the die 70 are reciprocable in the direction of the arrow 74 towards and away from the mold 10. In operation, the blank 50 must be placed on the mold cavity 12a and held down by a spacer frame 46, as in FIG. Figures 1-2, the extruder 22 and the die 70 are placed across the blank 50, and the desired layer of hot plastic is deposited thereon. The thickness of the plastic layer is given by the speed of displacement, the exit of the extruder and the dimensions of the die, all controlled in a conventional manner. At the end of the transverse displacement, the extruder is inactivated and returns to its initial position. One can provide an extruder with a width and / or thickness control to control the thickness and / or width of the plastic layer. The transverse displacement speed and / or the output of the extruder can be variable. The placement of the extruder in the X, Y and Z planes can be variable to vary the dimensions and / or the configuration of the plastic layer. The advantage of this procedure is in the lower tool costs. However, it can only be used when a progressive deposition, against a simultaneous one, with a hot slide is acceptable, for example, for narrow parts that require a relatively short extruder transverse displacement.

An important feature of the present invention is the uniformity of heating the film or white without having to resort to external means, and ensuring that the shaping operation is carried out simultaneously, the film or the blank and the supporting layer , followed by the application of molding pressures high enough to provide mold shaping of both. The finishing of the film in this way is conserved and the optically detectable imperfections are avoided. In addition, this procedure requires a much lower clamping pressure compared to conventional methods. Although the above procedure is primarily designed as an application on the outside of vehicles, it should be noted here that many other types of components could benefit from the present compression molding process with a color finish and with a precision molded article, particularly for large home devices and architectural components. With reference to the variation of Figure 4, the platen 80 is shown with an elastomeric forming mandrel 82 therein containing air slots 84 and a pressure control means 86 connected thereto. The mold 88 is shown with a mold cavity 90 therein, a film 92 and a holding frame 94 for holding the film on the edge 96 of the mold. The hot plastic 98 is deposited on the film 92 as in the previous modalities. As shown in the embodiment of Figure 4, the slots 84 intersect a multiple slot 100 which is connected to a source of fluid pressure, such as air. In operation, the elastomeric mandrel 92 enters the holding frame 94. Air under pressure is applied to the grooves 84 by expanding the grooves in the passages. Therefore, pressure is applied to the plastic 98 already deposited to the film 92. The pressure is present in the mold cavity 90 as in Figures 1-3, and the pressure is controllably released at the same time, resulting in the molding by blowing the plastic 98 and the film 92. The mandrel 82 moves simultaneously downward in the direction of the arrow 102. As the plastic and film reaches the surface of the mold, the mandrel continues and due to its plastic nature is adapted to the plastic surface moving away from the film, and the pressure continuing through the platen exerts hydrostatic pressure on the plastic. That pressure can be much greater than what could be economically available from a compressed fluid, for example greater than 6895 kPa (1000 psi). The upper part or inner surface of the finished part will be substantially parallel to the surface of the mold. The mandrel is preferably cooled, as is the mold. The above process represents an improved method and apparatus for forming large and thick parts similar to panels, because they solve the difficulty of uniformly heating a thick plate. It is useful, whether or not a color or painted film is required. Any plastic film can be used as a support for the hot plastic as long as it is compatible with the plastic to be molded. Compatibility can be obtained by various methods such as melt bonding, the use of adhesives or adherent layers. Alternatively, in some cases one can use an unsupported or removable film layer. Alternatively, one can use a second layer 93 of film (see Figure 4) under the main film layer 92 to provide additional support for the main film layer 92. For example, a second layer of film may be placed on the mold cavity to hold a thinner and brittle film or multiple films in position, or to hold a logo or decal 93 'on the film 92. Naturally, the second film of Desirable way can be transparent, and naturally also the second film can be used with any of the embodiments of the present invention. Desirably, the second film will be fixed to the mold in the same manner as the main film. Figures 5, 6 and 7 show detailed variations of the present invention. As shown in Figure 5, the film 110 is held on the mold cavity half 112 by the frame 114 and the molten plastic deposited thereon by the manifold 116 via the outlets 118 in the direction of the arrows 120. mold cavity half 112 includes cooling and compressed air channels 122 or vacuum channels 124 to provide air pressure under the film 110 or to aid in the forming process. The temperature of the film sheet is adjusted according to the extent of deformation that will be experienced. The molten film-plastic combination is compression molded into the mold cavity half after removal of the manifold 116 from between the mold halves via the core half 126 which contains the cooling channels 128. The finished molded article including the film and the deposited plastic is then formed between the mold cavity and the mold core. Figure 6 is similar to that of Figure 5, with the use of a transverse extruder 130 which extrudes a layer 132 of molten plastic on the film 110. Air cooling nozzles 134 can be provided to adequately condition the temperature of the layer 132 of molten plastic. Both the extruder 130 and the cooling nozzles 134 are movable from a position above the film 110, as shown in FIG. 6, to a position separated from the film 110 to allow coupling of the core half 126 with the melted film-plastic combination.

Figure 7 shows the film inserter 140 and the film feed means 142 for feeding a film 144 to the mold 146 above the mold cavity half 148. The hot plastic supply means 5 5 reciprocable, movable in the direction of the arrow 152, is provided adjacent the mold 146 to prepare a molded product 154 as in the previous embodiments. In the embodiment of figure 7, a insert part 156 of metal or plastic can be fed to the mold so that it forms part of the product 154 molding, as shown. Alternatively, a fiberglass mat or grid may be used as a reinforcement, or any suitable or desired reinforcement or functional material, such as random fiberglass material, textiles, metal, plastic, etc. One can reinforce the entire structure or selectively stiffen the structure as required. The product removal robot 158 is provided adjacent the mold 146 to remove the molded product. The molded product, of course, can have a variety of uses, such as, for example, side panel 160 for a car 162. Figure 8 shows a closed mold 170 with a cavity portion 172 and a core portion 174. The molded article includes a layer 176 of film, a plastic layer 178 and reinforcing material or fasteners 180. The material of The reinforcement or fastener 180 can be applied to the core portion 174 in order to provide the exact position on the molded article. When the mold 170 is closed, the fastener or the like can be ejected via an ejection passage 182 or any other means desired to firmly attach or to embed in the plastic layer. The ejection can be, for example, by a hydraulic or mechanical means. The reinforcements or fasteners can be selectively placed on the molded article, as shown in Figure 8, or they can completely cover the molded article. Alternatively, the assembly of the frame, film, plastic layer assembly can be prepared in an upstream position separated from the mold, for example, on a removable board. All preconditioning operations can be performed before the assembly is deposited in the mold and the only step performed by the mold is the final shaping operation. This will result in an assembly line type operation with the assembled and preconditioned plastic-films held in a frame transferred to the mold for final shaping. As a further alternative, one can use as an extrusion for the molten plastic. The plastic of a die can be extruded in co-layers or in multiple passes from two heads to deposit polymers and / or different compositions and / or fillers.

As a further alternative, one can use a variety of film types, such as a conductive film (EMI-RFI), a film with UV and / or infrared absorption characteristics, or any desired and convenient film with the desired range of properties to obtain particular results. Therefore, according to the present invention, a blank of die cut film is placed on the mold cavity. It is cut to match the edge of the cavity so that it only overlaps to allow clamping, the structural plastic is applied to the target while the cavity beneath it is pressurized enough to support the weight of the plastic. It is supplied either from a hot slide or a modified hot slide or from a transverse displacement extruder. It is then conditioned, for example, by cooling nozzles to acquire a pre-established temperature distribution point by point, including the film or target. The mold is closed by a mold core, while the pressure in the cavity is released and the cavity is evacuated. The molded article can be provided with inserted elements of an elaborate structure of a metal or different plastics including, for example, a grid, fibers, woven or non-woven mats, etc. The core compresses the plastic which is coated on the core side of the film. If a paint film is used, the part can obtain a class A finish, as it is molded. Due to the controlled deformation parameters of color depth, the thickness of the deformed film can maintain uniform brightness and color depth after molding. To finish the process, the part is cooled in the mold, which is controlled in terms of temperature. No mechanical ejectors are needed and no ejector marks are left: when opening the mold, the part is separated from the surface of the mold by any means desired, for example by air expellers, using the channels that were used as the outlet to make " float "the carrier film, and transferred by suction to the end of the robot arm. Unlike injection molding, this procedure is based on the following considerations. In the injection molding process, the molten plastic is propelled through a small hole into a large space bordered by walls that are intensely cooled. The filling of the mold occurs by coating the walls of the mold and filling the space diminished between them progressively, under conditions of laminar flow. This phenomenon, called tunnel flow, makes co-injection possible. The melt and then the gradually solidifying plastic is cooled inwardly from the mold wall, through the first coating and the attached laminar structure, into a material that is a poor heat conductor. The speed and amount of shrinkage from the melt to the solid varies according to layer by layer, and depends on the changes in the wall thicknesses point by point. The passage through the melting transition temperature, T, particularly in crystalline plastics, severely interferes with the performance of the plastics upon molding. Therefore, the flood marks oppose to the vestige of gate and in opposition to a thick reinforcement, and the formation of waves of larger surfaces. Another very serious consequence of volume change to T in large thin injection molded panels of variable curvature, may be the residual stresses of the wrapping surfaces as they are released, for example, by environmental exposure, as the temperature increases or when absorbs corrosive moisture; this, in addition to another expected consequence of voltage concentrations. The solution to this almost intractable problem is to eliminate the Th - caused by a change in volume in the molding process. This is precisely what the compression molding of the present invention accomplishes. As an alternative embodiment, one can provide a plastic film, covered with molten plastic as above, covered in turn with a reinforcing material. The male mold can press the components together and embed the reinforcement material in the plastic. Alternatively, one can provide an additional layer of molten plastic material on the reinforcement material, effectively incrusting the reinforcement material between the two layers of plastic. The present invention acquires important advantages with respect to injection molding processes. Therefore, the present invention results in minor investments in equipment and tools. Additionally, the use of paint films to produce finished structural panels eliminates the need for expensive investments in a paint plant, and eliminates all environmental concerns regarding paint since the film can be made in a closed and environmentally safe chamber. In addition, preforming of the film is not required to produce class A structural components. Cycle times are faster than injection molding. The forming pressures are lower than those of conventional injection molding. In addition, the open mold nature of the current process and apparatus allow selective insertion of reinforcements or additional components, such as fasteners, logos, advertisements, designs or the like. It is to be understood that the invention is not limited to the illustrations described and shown herein, which are considered only as illustrative of the best modes for carrying out the invention, and which are susceptible to modification as to form, size, disposition of parts and operation details. Rather, it is intended that the invention encompass all such modifications which are within their spirit and scope, as defined by the claims.

Claims (33)

1. A process for preparing a molded article, which comprises: providing a mold cavity; place a film on the mold cavity; depositing molten plastics on the film to form a combination of a film with molten plastic thereon; and subsequently forming the molten film-plastic combination into the mold cavity, into a molded article having the shape of the mold cavity, wherein the film is an outer layer of the molded article.

2. The process as described in claim 1, wherein the film is held over the mold cavity and the molten plastic is deposited on the film.

3. The process as described in claim 2, wherein the molten film-plastic combination conforms to the shape of the mold cavity, at least in part psr_ a mold core which compresses the combination and forms the combination to the shape of the mold cavity.

4. The process as described in claim 1, wherein the film is colored.

5. The process as described in claim 2, including the step of depositing molten plastic on the film from a supply means of. hot plastic placed adjacent to the mold.

6. The process as described in claim 5, which includes the step of depositing the molten plastic on the film from a hot slide having a plurality of molten plastic outlets positioned adjacent to the film. __ _

7. The process as described in claim 5, which includes the step of depositing the molten plastic on the film from a delivery medium which traverses the film.

8. The process as described in claim 5, wherein the molten film-plastic combination is formed at least in part by fluid pressure.

9. The process as described in claim 5, wherein the molten film-plastic combination is formed at least in part by a mandrel.

10. The process as described in the claim 1, which includes the step of including an insert or a different material attached to the molded part.

11. The process as described in claim 1, including the step of depositing molten plastic differential thicknesses on the film.

12. The process as described in claim 1, including a second support film on the film between the film and the mold cavity.

13. The process as described in claim 1, including the step of holding the film on the mold cavity in a channel of a frame member.

14. The process as described in claim 1, which includes the step of holding the film on the mold cavity in a frame member and providing at least a suction flow and air directly below the film through the frame member .

15. The process as described in claim 13, including the step of releasing the film from the channel during shaping to minimize scraping edges and reducing localized film thinning.

16. The process as described in claim 1, wherein the film is held on the mold cavity by air pressure.

17. The process as described in the claim 16, in which the air pressure is variable.

18. An apparatus for preparing a molded article, comprising: a mold cavity; means for holding a film on the mold cavity; means for depositing molten plastic on the film to form a combination of a film with plastics effused thereon; and a means for shaping the molten film-plastic combination subsequent to the molten plastic reservoir on the film in the mold cavity, in a molded article having the shape of the mold cavity, wherein the film is an outer layer of the mold cavity. molded article.

19. The apparatus as described in the claim 18, in which the means for fastening is a support frame, and wherein the means for depositing, deposits molten plastic on the film while the film is held in the frame on the mold cavity.

20. The apparatus as described in the claim 19, which includes a mold core which conforms, at least in part, to the molten film-plastic combination in the shape of the mold cavity by compressing the molten film-plastic combination and shaping the combination to the shape of the mold cavity.

21. The apparatus as described in claim 18, wherein the film is colored.

22. The apparatus as described in claim 19, including a hot plastic supply means positioned adjacent the mold cavity for depositing molten plastic on the film.

23. The apparatus as described in claim 22, including a hot runner with a plurality of molten plastic outlets positioned adjacent the film to deposit molten plastic on the film.

24. The apparatus as described in claim 22, including a molten plastic supply means for depositing molten plastic on the film as it passes through the film.

25. The apparatus as described in claim 22, including means for applying fluid pressure to the combination to form, at least in part, the molded article.

26. The apparatus as described in claim 22, including a mandrel for shaping, at least in part, the combination in a molded article.

27. The apparatus as described in the claim 18, which includes a means for including an insert or a different material attached to the molded part.

28. The apparatus as described in claim 18, including means for depositing differential thicknesses of molten plastic on the film.

29. The apparatus as described in claim 18, including means for including a second support film on the film between the film and the mold cavity.

30. The apparatus as described in claim 18, which includes a frame member with a channel in the same operative to hold the film on the mold cavity in the channel.

31. The apparatus as described in claim 18, including a frame member operative to hold the film on the mold cavity, and a channel means for providing at least one suction and air flow directly below the film to through the frame member.

32. The apparatus as described in claim 18, wherein the means for holding a film on the cavity includes a means for providing air pressure under the film.

33. The apparatus as described in claim 32, wherein the means for providing air pressure below the film is operative to provide variable air pressure.