Patent ID: 6126881
Filing Date: 2000-10-03
Classification: B29C,B29K

Abstract:
A process for forming a product using a hollow cavity mold having a lower cavity and an upper cavity and a rotomolder machine having a oven, the process comprising the steps of:(a) forming first and second color powders, said first and second color powders comprising a blend of a ground powder made from a virgin polyethylene having a particle size of about 35 mesh and first and second dry color pigments, respectively;(b) placing said first and second color powders into a pre-determined pattern within the lower cavity of the hollow cavity mold;(c) closing said hollow cavity mold;(d) placing said hollow cavity mold into said oven;(e) heating said hollow cavity mold with no rotation for a first period of time defined by the heating time necessary for a layer of said first and second color powders to melt in the desired pattern upon the lower cavity and form an epidermal layer;(f) rotating the hollow cavity mold in a bi-axis manner while heating said hollow cavity mold for a second period of time defined by the heating time necessary to completely melt and combine the remaining first and second color powders in the hollow cavity mold into a sum color of the individual colors;(g) cooling said hollow cavity mold to solidify the product; and(h) removing the product from said hollow cavity mold, the product comprising a pattern having a first color corresponding to said first color powder and a second color corresponding to said second color powder.