Patent ID: 8071000
Filing Date: 2011-12-06
Classification: B29C,B29K,B29L,B32B,Y10T

Abstract:
1. A process for manufacturing a multi-layer composite product of injection molded plastic comprising: (a) providing a moveable mold part comprising at least a first mold core; (b) providing a stationary mold part comprising at least a first mold cover including a first cavity, and a second mold cover including a second mold cavity, the second cavity of greater volume than the first cavity; (c) positioning a decorative layer on the first mold cover across at least a portion of said first cavity; (d) aligning the first mold cover with the first mold core to form a first injection volume; (e) injecting a first polymeric material into said first injection volume between said decorative layer and said first core, causing said decorative layer to conform to the shape of said first cavity and solidifying said first polymeric material to form a decorative composite; (f) sequentially moving said first mold core including said decorative composite with respect to the stationary mold part to selectively align the first mold core including said decorative composite with the second mold cover, the second mold cover and said first mold core including said decorative composite forming a second injection volume; (g) injecting a second polymeric material into the second injection volume formed between said decorative composite and said second mold cover to form an outer layer, wherein at least one of said first polymeric material and said second polymeric material comprise a clear plastic; and (h) solidifying said second polymeric material to form a composite product.