Patent ID: 6803008
Filing Date: 2004-10-12
Classification: B29C,B29K,B29L

Abstract:
A method of making a molded device having a resin-rich layer overlaying at least a portion of the outer layer of the device and integrally attached thereto, the method comprising the steps of:installing a layer of resin-rich material within a mold die, the resin-rich material having a melting point, and the mold die having an interior surface and at least one contour defined therein; introducing a volume of injectable moldable substrate into the mold die having the layer of resin-rich material installed therein, the injectable moldable substrate introduced into the mold die in an essentially molten state at a temperature above the melting point of the resin-rich material, the volume of injectable moldable substrate having sufficient heat to completely melt the resin-rich material installed in the mold die, the injectable moldable substrate introduced into the mold die such that the resin-rich material is interposed between the mold die and said injectable moldable substrate and is forced into contact with the interior surface of the mold die an the contour located therein in a manner which achieves substantially uniform bonding between the resin-rich material and the injectable moldable substrate immediately adjacent thereto along the entire area between the resin-rich material and the injectable moldable substrate; permitting the resin-rich material and the injectable moldable substrate to cool to a temperature at which the substrate is in a substantially solid form.