Abstract:
Molding methods and systems are disclosed for manufacturing molded items ( 10 ) with an integral substrate ( 50 ) formed thereon, particularly wherein the substrate has a metallic appearance and/or wherein the molded product is formed with a geometric feature ( 66 ) associated with an edge of the substrate adapted for at least partially obscuring the edge in the molded product.

Description:
FIELD OF THE INVENTION 
     This invention relates to methods and apparatuses/systems for making a product. More particularly, the present invention relates to methods and apparatuses/systems for making a product by injection molding and to molded products made thereby. 
     BACKGROUND OF THE INVENTION 
     Injection molding processes are well known, and generally involve injecting a flowable material such as a plastic into a cavity prepared in a mold, and allowing the material to cool and harden to form a product that has a form generally complementary to that of the mold cavity. 
     In a variation of such processes, a film may be integrally formed on the product by inserting the film or substrate into the mold prior to the injection of the molten material. 
     US2005/140055 discloses a method for making a part by injection molding and decorating a visually-exposed face surface and a visually-exposed side surface of the part in their entireties during the injection molding of the part. The method includes the steps of providing a mold, inserting a decorative film into the mold, closing the mold, injecting a molten material into the mold causing the decorative film to conform to the mold by virtue of the molten material, when filling the mold, exerting a force on the decorative film forcing the decorative film to abut intimately against the mold, hardening the molten material so as to form a hardened core, and forming the part with the decorative film being adhered to the hardened core, by virtue of the decorative film being possessed by the hardened core when the molten material hardens and becomes the hardened core, so as to allow the decorative film to cover the hardened core and thereby eliminate a concern for color inconsistency of the hardened core caused by color variations of the molten material by virtue of the hardened core being covered by the decorative film. 
     U.S. 2003/0122278 discloses a method for applying multiple decorative sheets of film to an injection-mold component as a part of the injection mold process. Two sheets of film having desired images are permanently affixed to the surfaces of the injection mold component as a part of the injection molding process. An enhanced three-dimensional appearance is achieved by affixing the images to a transparent injection mold component. 
     U.S. Pat. No. 4,052,497 discloses a method for the manufacture by injection molding of articles composed of a plurality of layers of at least three distinct materials coated one over the other. The method includes the steps of successive injection of a measured quantity of a first material adapted to form the skin of the article, a measured quantity of a second material to form the intermediate layer, and a measured quantity of a third material to form the body of the article. The materials are introduced into the mold coaxially so as to give a uniform distribution. The method is especially applicable to the production of articles in which the external and internal materials are joined together by an intermediate material. 
     U.S. Pat. No. 4,686,076 discloses a method, machine, and mold for fabricating, by injection of synthetic material, containers having a film forming an external coating. The machine includes a mold, an injection nozzle, a film feed device, and apparatus for holding the film against the male element of the mold. The injection nozzle is carried by the male element of the mold and the holding apparatus includes a slider in the cavity of the female element movable, under the action of the male element, against a return force. 
     U.S. Pat. No. 5,240,751 discloses a decorative automotive vehicle trim strip and method and apparatus for forming by reshaping an end of a previously extruded length of thermoplastic material. The surface of the length of the thermoplastic material intended for viewing is maintained at a cold temperature, well below the softening point of the thermoplastic material, during the reshaping operation. The length of the thermoplastic material is heated during reshaping by a mold section heated to 400 degrees F. to 410 degrees F. pressed against the surface intended to be affixed to the vehicle. 
     U.S. Pat. No. 5,415,536 discloses a method for forming a pattern onto an article during injection molding thereof. A pattern-bearing film is heated and softened by a heating board. The softened pattern-bearing film is transferred to the cavity surface of a female mold. Thereafter, the female mold and a male mold are closed. Then, a molten resin is injected into the cavity. When the pattern-bearing film is brought into contact with and heated by the heating board, marks or impressions of air blow holes on the surface of the heating board remain on the pattern-bearing film. To prevent the formation of these marks or impressions, a square-shaped holding frame is fixed on the surface of the heating board. The peripheral portion of the pattern-bearing film is held on the surface of the holding frame. Thus, while the pattern portion of the pattern-bearing film is spaced apart from the surface of the heating board, the film is heated. To keep the pattern-bearing film uniformly spaced from the surface of the heating board, air is supplied to the inside of the holding frame. 
     U.S. Pat. No. 6,090,336 discloses a method and apparatus for manufacturing an injection-molded article having an outer film on an exposed surface. The method includes securing the film about its periphery within a mold cavity prior to injection of molten material into the cavity. One way of securing the film is by applying vacuum pressure through peripheral holes in a frame surrounding the mold cavity. Molten material is injected into the cavity behind the film, and the film slips from its initial position to be forced against a wall of the cavity by molten material being injected into the cavity. The apparatus includes a frame for a molding apparatus adapted to initially secure the film in place prior to movement of the core block into place and to permit the film to slip from its initial position to be forced against the cavity wall as molten material fills the cavity. 
     U.S. Pat. No. 6,474,976 discloses a film holding apparatus for an injection mold which is capable of surely holding a protective film on a specific position of a mold surface of the injection mold. The film holding apparatus for holding an inner film on the mold surface of the injection molds consisting of two coupled molds having substantially-vertical coupled surfaces thereof which includes two positioning pins that can hang an upper edge side of the inner film on an upper edge portion of the mold surface of the mold, and upper and lower vacuum opening portions for film adsorption disposed so as to interpose the positioning pins therebetween from the upper and lower sides. The upper vacuum opening portion is formed in a line which extends along an upper edge of the mold surface. 
     SUMMARY OF THE INVENTION 
     Herein, “metallic layer” includes a layer, sheet, net, mesh, strips, foil or the like, made from a material or having a coating comprising a metal or metallic material, and/or comprising a material having the appearance of a metal or metallic material, wherein the “metallic layer” includes a material that is electrically conducting, as opposed to a dielectric material including dielectric materials that may have a metallic-like appearance. 
     By “visually exposed” with respect to a surface of a part is meant a surface of the part that may usually be seen from particular desired viewing directions when the part is in at least one intended position or location, or from the most common viewing direction for the part. For example, if the part is a box or bin cover that is normally closed, the visually exposed surface thereof may be the upper surface of the cover, this being seen from the regular viewing directions, as opposed to the underside of the cover, which may only be seen when the cover is in the open position or from inside the box or bin. 
     According to a first aspect of the invention, a manufacturing method is provided, comprising: 
     providing a substrate, comprising at least one electrically conducting layer overlaid with at least one dielectric outer-facing layer, and further comprising an inner-facing surface; 
     applying an electrostatic charge to said outer-facing layer; 
     electrostatically holding said substrate in a desired position within a mold cavity; 
     injecting a suitable molten material into said mold cavity in a manner such that at least a layer of said molten material possesses said substrate via said inner-facing surface. 
     The visually exposed surface has a metallic appearance. 
     In particular, a method for manufacturing molded items having at least one visually exposed surface is provided, comprising: 
     (a) providing a mold having a molding surface generally complementary to said visually exposed surface; 
     (b) providing a substrate, comprising at least one electrically conducting layer overlaid with at least one dielectric outer-facing layer, and further comprising an inner-facing surface; 
     (c) applying an electrostatic charge to said outer-facing layer; 
     (d) electrostatically holding said substrate in a desired position within said mold such that said outer-facing layer is in at least partial abutment with said molding surface; 
     (e) injecting a suitable molten material into said mold in a manner such that at least a layer of said molten material is formed in overlying relationship with said inner-facing surface; and 
     (f) allowing the molten material to solidify and possess said substrate. 
     Optionally, the substrate may further comprise a dielectric inner-facing layer defining said inner-facing surface. 
     The electrically conducting layer may comprise a metallic material, including for example a metallic foil. The electrically conducting layer may comprise at least one opening therethrough or may be substantially continuous. The electrically conducting layer may comprise a metal or an alloy including at least one of: aluminium, silver, oxidized silver, gold, titanium, copper, tin, steel, stainless steel, galvanized steel, nickel, magnesium. 
     The outer-facing layer may have a thickness of between about 30 micron and about 400 micron; the electrically conducting layer may comprise a thickness of between about 5 micron and about 15 micron, or between about 15 micron and about 30 micron, or greater than about 30 micron. 
     Optionally, step (c) comprises holding the substrate in a configuration generally corresponding to the form to be adopted by the substrate in step (f), providing a ground reference surface facing said inner-facing surface, and establishing a suitable electric field between an electric charger and said ground reference surface. Optionally, the substrate may be configured in the form of a loop, including, for example, a cylindrical loop, frustroconical loop, etc. 
     In step (e), the molten material may be injected into the mold causing the substrate to conform to the mold surface by virtue of the molten material, when filling the mold, exerting a force on the substrate forcing the substrate to abut intimately against the mold surface. 
     Optionally, the mold may be in particular configured for forming a geometric feature in an item molded therein, said feature being associated with an edge of said substrate and adapted for at least partially obscuring said edge. The geometric feature may comprise a recess in the molded item, wherein said substrate edge is located at least partially projecting into said recess. Alternatively, the geometric feature may comprise a raised step formed on a visually exposed surface of said molded item, wherein said substrate edge is located in close proximity to said step. 
     According to the second aspect of the invention, a method for manufacturing molded items having at least one visually exposed surface is provided, comprising: 
     providing a mold having a molding surface generally complementary to said visually exposed surface; 
     providing a substrate, comprising said at least visually exposed surface and an inner-facing surface; 
     holding said substrate in a desired position within said mold with said visually exposed surface facing said mold surface, and injecting a suitable molten material into said mold in a manner such that at least a layer of said molten material is formed in overlying relationship with said inner-facing surface, and allowing the molten material to solidify and possess said substrate; 
     wherein said mold is configured for forming a geometric feature in an item molded therein, said feature being associated with an edge of said substrate and adapted for at least partially obscuring said edge. 
     The geometric feature may comprise a recess in the molded item, wherein said substrate edge is located at least partially projecting into said recess, or alternatively a raised step formed on a visually exposed surface of said molded item, wherein said substrate edge is located in close proximity to said step. 
     The substrate may comprise at least one electrically conducting layer overlaid with at least one dielectric outer-facing layer, and further comprising an inner-facing surface, wherein said outer-facing surface comprises said visually exposed surface. Optionally, the substrate may further comprise a dielectric inner-facing layer defining said inner-facing surface. Alternatively, the substrate may be a dielectric substrate. 
     Thus, the substrate may be fully dielectric or may comprise at least one at least one electrically conducting layer. 
     The invention also relates to molded items manufactured according to the manufacturing process of the invention. The item may comprise, by way of non-limiting example, a cylindrical form, a frustoconical form, a substantially box-like form, and so on. The item may comprise, by way of non-limiting example, any one of bathroom furniture and accessories, home storage boxes, kitchen furniture and accessories, vehicle accessories, and the like. The item may comprise, by way of non-limiting example, any one of bins, toilet brush containers, toilet tissue dispensers; vehicle body trims, wheel hub covers, side mirror housings, and the like. 
     The present invention also relates to a system for manufacturing molded items having at least one visually exposed surface, comprising: 
     a mold having a molding surface generally complementary to said visually exposed surface; 
     a substrate, comprising at least one electrically conducting layer overlaid with at least one dielectric outer-facing layer, and further comprising an inner-facing surface; 
     an electric charging device adapted for applying an electrostatic charge to said outer layer; 
     a positioning mechanism for positioning a substrate within the mold such to enable the substrate to be electrostatically held in a desired position within said mold such an outer charged layer thereof may be in at least partial abutment with said molding surface; 
     an injector arrangement for injecting a suitable molten material into said mold in a manner such that at least a layer of said molten material is formed in overlying relationship with said inner-facing surface. 
     Optionally, the system further comprises a magazine having a stack of said substrates, and wherein said positioning mechanism is further adapted for taking a single substrate at a time from said stack and transporting the same to the mold. 
     According to aspects of the invention, molding methods and systems are disclosed for manufacturing molded items with an integral substrate formed thereon, particularly wherein the substrate has a metallic appearance and/or wherein the molded product is formed with a geometric feature associated with an edge of the substrate adapted for at least partially obscuring the edge in the molded product. 
     According to the invention, a wide variety of articles of manufacture may be provided, having a visually desirable and realistic/authentic metallic finish, and at the same time avoiding undesirable consequences that may sometimes arise when similar articles are manufactured primarily from metals. Examples may include bathroom furniture and accessories including for example bins, toilet brush container, toilet tissue dispenser; kitchen furniture and accessories; vehicle accessories, for example trims, wheel hub covers, side mirror housings etc. Many such articles, when made primarily from a metal, may be susceptible to denting, rusting or other problems, or may be undesirably heavy or costly. The present invention provides such articles made from a plastic material or other material that may be used in an injection-molding process, but including a visually exposed metallic layer embedded therein, providing a desirable metallic finish to such products. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order to understand the invention and to see how it may be carried out in practice, embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which: 
         FIG. 1  is an isometric view of an embodiment of an article manufactured according to the invention. 
         FIG. 2   a  shows in cross-sectional view a portion of the article of  FIG. 1 , including details of an embodiment of a substrate according to the invention.  FIG. 2   b  shows the substrate of  FIG. 2   a  having a generally rectangular planform. 
         FIGS. 3   a  to  3   d  illustrate various steps in the manufacture of a part of the embodiment of  FIG. 1   
         FIG. 4  illustrates a step in the manufacture of another part of the embodiment of  FIG. 1   
         FIG. 5  illustrates, in partial cross-sectional view, a feature of part of the embodiment of  FIG. 1 , according to another aspect of the invention. 
         FIG. 6  illustrates, in partial cross-sectional view, a feature of another part of the embodiment of  FIG. 1 , according to an aspect of the invention. 
         FIG. 7  illustrates, in partial cross-sectional view, another embodiment of an article manufactured according to the invention. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     A first embodiment of an item of manufacture produced according to the invention, designated with the numeral  10  and referred to herein interchangeably as an “article”, “part” or “product”, is illustrated in  FIG. 1 . The product  10  according to this embodiment may be, by way of non-limiting example, a closable bin, having a lower container part  20  of general cylindrical form having a length dimension L and an outer diameter D defining a fillable volume V, and a lid  30  that is hingedly or otherwise releasably coupled to the lower part  20 . The lower part  20  has a visually exposed cylindrical surface  21  of particular interest and an upper rim  25 , and is mounted onto a base  23 . The lid  30  comprises a visually exposed flat or convex disk-like surface  31  of particular interest and annular rim  33 . 
     According to a first aspect of the present invention, a method and system are provided for manufacturing parts  20  and  30  via a novel injection molding process, wherein said visually exposed surfaces  21  and  31  may have a metallic appearance. 
     The metallic appearance of visually exposed surfaces  21  and  31  is obtained by individually injection-molding each of the parts  20 ,  30  in turn, each with a suitable substrate  50  held in place within the corresponding mold, as will be described in greater detail herein. Referring to  FIG. 2   a , the substrate  50  comprises an electrically conducting metallic layer  55  laminated or otherwise sandwiched between an outer-facing electrically insulating dielectric layer  51  and an inner-facing electrically insulating dielectric layer  53 , bonded to the metallic layer  55  by layers or adhesive  52 ,  54 , respectively. Optionally, the outer-facing surface of inner layer  53  and the inner-facing surface of outer layer  51  may be activated by any suitable method, for example a plasma, corona, flame or chemical treatment, to produce a treated layer. Optionally, the outer layer  51  is scratch resistant, while the inner layer  53  is adapted for being possessed by a molten material used in an injection molding process, when in contact therewith. 
     Thus, the outer layer  51  and the inner layer  53  are individually formed, and then bonded to the metallic layer  55  via adhesives, which optionally may be thermo and/or UV cured, which optionally may be water based or solvent based, and so on. Alternatively, the layers  51 ,  55 ,  53  may be bonded mechanically or via ultrasonic welding or in any other suitable manner. 
     Alternatively, the layers  51 ,  53  may be otherwise bonded or formed over the metallic layer  55 , for example using suitable coating, thermoforming or printing techniques, etc. For example, the layers  51 ,  53  may be formed over the metallic layer  55  as a lacquer or coating (for example PU, acrylic, cellulose, alkyd, and so on, which may be coated over the metallic layer  55  using any suitable method, for example by evaporation of solvents, self-cross-linking, thermo-curing, UV curing and so on. 
     Alternatively, the dielectric/metallic layer sandwich construction of the substrate  50  may be achieved by covering the inner-facing part of outer layer  51  and/or the outer facing part of inner layer  53  with metallic layers using a suitable electrochemical; process, for example by means of electrostatic powdering in cold and/or hot state; hard coating in plasma chambers, etc. 
     Alternatively, the dielectric/metallic layer sandwich construction of the substrate  50  may be achieved by covering the metallic layer  55  with polymers, for example via thermal processes, including, for example, heat transfer coloring processes, heat laminating processes, etc. 
     The metallic layer  55  may be in the form of a substantially continuous metallic foil, or alternatively may comprise cutouts of any desired design, for example a decorative pattern or company logo, or the layer  55  may be in the form of a net or mesh, and the layers  51 ,  55 ,  53  may be bonded together by heat welding or otherwise bonding the inner layer  53  to the outer layer  51  to one another directly via the cutouts. 
     The outer layer  51  is preferably optically transparent, and optionally shaded in any desired colour, to allow the colour (original or modified via layer  51 ) and texture of the metallic layer to be readily seen via the outer layer. The inner layer  53  may be transparent, translucent or opaque, and have any desired colour. 
     Optionally, further intermediate layers, which may be metallic or non metallic, may be provided in the substrate  50  to provide any desired metallic appearance in the surfaces  21  and  31 . 
     By way of non-limiting example, the metallic layer  55  may comprise a foil made of any one of aluminium, silver, oxidized silver, gold, titanium, copper, tin, steel, stainless steel, galvanised steel, nickel, magnesium, or any other suitable metal, which may be in elemental metal or alloy form, for example. Optionally, the metallic layer  55  may be formed from a number of different metals suitably juxtaposed and/or superposed with respect to one another. Further by way of non-limiting example, the metallic layer  55  may be between about 5 micron and about 15 micron thick, or between about 15 micron and about 30 micron thick, or thicker than about 30 micron. The metallic layer  55  may optionally be pre-treated, for example coated with a suitable primer, adhesive, paint, etc, prior to being formed into said substrate  50  and/or prior to being subjected to injection molding according to the invention. 
     Further by way of non-limiting example, the substrate  50  may be between about 60 micron and about 200 micron thick, or thicker than 200 micron; the inner layer  53  may be made from material that is suitable for use in plastic injection technology, in particular for intimately fusing with injected plastic in contact therewith in a mold, during the molding process, and may include, by way of non-limiting example, any one of bi-oriented polypropylene (BOPP), for example about 20 to about 50 micron thick, or from extrusion direction oriented polypropylene (OPP), for example about 20 to about 150 micron thick, or from cast polypropylene (CCP), for example about 30 to about 200 micron thick; the outer layer  51  may be made from polyethylene-terephthalate (polyester) (PET), for example about 12 micron thick, or up to about 200 micron thick, or greater, or from different other transparent polyesters (for example PETG), or from poly-methyl-met-acrylate (Acrylic) (PMMA), for example about 60 to about 70 micron thick, or up to about 200 micron thick, or up to about 400 micron thick or greater, or from PC or from transparent polyamides, for example PA-11, PA-12, PEBA, or from PS-derivatives, including for example GPPS, SAN, MABS, SBS, K-resins etc. of suitable thickness. The layer  51  may be both rigid and soft (e.g., transparent soft-touch TPE-s, TPV-s, based for example on PU-s, SBS-s, SEBS-s, etc.). 
     In particular, the outer layer  51  comprises a thickness sufficient to retain a suitable electrostatic charge, for example between about 30 micron to about 200 micron, or greater, for example, for a duration of a few seconds, for example, such as to enable the substrate  50  to be externally charged and placed within a mold cavity, as will be explained in greater detail herein. Such a thickness may range from between about 30 micron to about 100 micron. Examples of suitable substrates  50  are commercially available. 
     The part  20  and lid  30  may also each comprise other surfaces which are not typically or are not intended to be visually exposed, at least most of the time or from the desired viewing angles of the visually exposed surfaces, and thus may constitute, for example, the inner-facing surfaces of the part  20  and lid  30 . Furthermore, there may be some visually exposed surfaces, for example rims  25 ,  33  of part  20  and lid  30 , respectively, which may not necessarily comprise a metallic appearance. 
     The process for manufacturing part  20  according to one embodiment of the invention will now be described. Referring to  FIGS. 3   a  to  3   d , a mold  100  is provided for producing the item  10 . The mold  100  comprises a first, female mold part  110  and a second, male mold part  120  which may be reversibly joined together to provide a mold cavity  130  in which the part  20  may be formed. The cavity  130  thus has a size substantially similar to, and a form or shape substantially complementary to, that of the item  20 , optionally taking into account factors such as springback, shrinkage and so on, where appropriate, as is known in the art. The first mold part  110  comprises a cavity  132  having a mold surface  122  corresponding to the visually exposed surface  21 , which in this particular example is substantially cylindrical. The second mold part  120  comprises a mating portion  125 , adapted for mating with mating portion  115  of the first mold part  110  at a parting line. The second mold part  120  also comprises core  128 , comprising cylindrical surface  126  and end surface  127 , substantially complementary to the unexposed inner surfaces of part  20 . When the mold parts  110  and  120  are coupled, the core  128  is received in cavity  132 , defining the mold cavity  130 . 
     The mold part  120  further comprises at least one injection station  145 , for example at the sides of the surface  126 , or at the center of end surface  127  (not shown), providing fluid communication between cavity  130  and an injection material source (not shown), at least when the mold  100  is closed and ready for use. 
     Optionally, the substrate  50  may be provided as pre-cut films, ready to be used with mold  100 . For example, and referring in particular to  FIG. 3   a , a magazine  160  may be provided holding a stack of superposed substrates  50 , as is known in the art. A robotic arm  170 , or other suitable positioning mechanism, is provided, configured for transporting, handling and positioning each substrate  50  in turn with respect to the mold  100 . The robotic arm  170  comprises an end-of-arm tool  172  in the form of a mandrel or dummy  174 , in this particular embodiment being in the form of a drum, having a number of suction ports  173  arranged on the cylindrical surface of the dummy  174 , and in fluid communication with a suitable suction source, for example a pump (not shown). 
     In operation, the dummy  174  may be brought into tangential proximity with an edge  59  of substrate  50 , which in this example is of a general rectangular planform having two orthogonally arranged pairs of edges  59 ,  58  (see  FIG. 2   b ). Edges  59  have a length substantially similar to dimension L of the surface  21 , and edges  58  have a length sufficient to enable the substrate to wrap around to form surface  21  of diameter D. An air nozzle arrangement  162  blows a stream of air to separate an uppermost substrate  50  from the stack, and this substrate  50  may then be grasped by a suitable transport mechanism  165 , which may comprise, for example, suction pads, and transported towards the dummy  174  until tangential contact is established therewith. A portion of the substrate  50  close to edge  59  is then grasped by the dummy  174  by means of suction ports  173 . The dummy  174  may be rotated about its axis  179  thereby winding the substrate  50  onto the cylindrical surface of the dummy  174 , and held there via additional suction ports  173 , the substrate  50  being disengaged from mechanism  165 . Alternatively, the substrate  50  may be lowered onto and draped over the dummy  174  using any suitable mechanism, and the suction ports  173  generate sufficient suction to wind the substrate onto the dummy. The substrate  50  is wound onto the dummy  174  such that the outer-facing layer  51  is outermost, and the inner-facing layer  53  is facing the cylindrical surface of dummy  174 . 
     Next, the robotic arm  170  transports and positions the dummy  174  generally coaxially coaligned with the cavity  132  of the mold part  110 , and spaced therefrom by spacing s. Charging applicator  190  is provided for applying an electrostatic charge to the outer-facing layer  51 . Charging applicator  190  may be, for example, in the form of a charging bar comprising a plurality of emitter pins or alternatively may be in the form of a individual emitter modules; the style and number of applicators generally depends on the size and shape of the substrate  50 , and the contours of the mold surface on which the substrate  50  is to be placed. An electrically grounded reference surface, such as a grounded metal plate, is provided in dummy  174 , and may comprise the cylindrical surface of the dummy. Optionally, a layer of antistatic foam material may be bonded to the cylindrical ground metal surface of the dummy  174 . 
     Charging applicator  190  is operatively connected to a high voltage DC electrical power supply, for example having a 30 kV adjustable output capacity, though in some embodiments, the charge required may be 15 to 20 kV, for example, and positioned in the path of the dummy  174  such that as this is transported and aligned with respect to the cavity  132 , an electrostatic charge is induced on the outer layer  51 . The ground reference surface, generally facing the inner surface  53 , attracts the electric field from the charging applicator  190  and the outer layer  51  of the substrate  50  becomes charged. For example the applicator  190  may be positioned within spacing s or at any other suitable location. Alternatively, the applicator may be integrated with the end-of-arm tool  172 . 
     The outer layer  51  of the substrate  50  is thus charged externally with respect to the mold or the dummy. 
     The charged substrate  50  is inserted into cavity  132  by the robotic arm  170  such that the outer layer  51  is axially aligned with the surface  122 . The suction at suction ports  173  is terminated and the substrate  50  is then attracted to and held on surface  122  by virtue of its charge, the mold part  110 , or at least a portion thereof defining the cavity  132  being electrically conducting and earthed at E. Optionally, air jets may be provided, for example at the dummy  174 , to blow the substrate towards the cavity  132 . The robotic arm  170  is then removed, and the mold parts  110  and  120  are mated, defining cavity  130  in which the substrate is appropriately aligned. 
     Referring in particular to  FIG. 3   c , the injection process is then initiated, molten material, typically a plastic material, in injected into cavity  130 , via suitable injections stations  145  located on mold part  120  and/or in mold part  110  (not shown), the injection stations being located such as to inject molten material towards the inner layer  53  of the substrate  50 , while generally avoiding injecting molten material directly to the outer layer  51 , particularly where this corresponds to the exposed surface  21 . The molten material possesses the inner layer  53 , and further the injection process also serves to push the substrate  50  into substantially full abutment with surface  122 , if this was not already the case. Once the injection material  199  has solidified, the substrate  50  is effectively integrally set with respect to the material  199 , to form intermediate workpiece  20 ′, which may then be removed from the mold part  110  or from mold part  120 , having previously separated the mold parts  110  and  120 . The same or a different robotic arm or positioning mechanism may be used for removing the workpiece  20 ′ from the mold  100 , via a suitable end-of-arm tool configured for so doing. 
     Optionally, a static neutralising bar  195  ( FIG. 3   a ) may be provided in the robotic arm path between the charging applicator  190  and the magazine  160 , so that whenever a new substrate  50  is being picked up the dummy  174 , and in particular the suction cups  173 , may be electrically neutralized, which helps to avoid electrostatic buildup at the suction cups  173 . 
     While the process above has been described with respect to forming a cylindrical surface  21  on part  20 , it may be applied, mutatis mutandis, to forming any other suitably-shaped surface, for example conical, frusto-conical, box-like, pyramidal, and so on, the substrate  50  being shaped appropriately so as to form the desired three-dimensional form when possessed by the material  199  in the mold. Similarly, in such cases the dummy  174  and the molding surface of mold  100  may also be shaped appropriately, for example, also conical, frusto-conical, box-like, pyramidal, and so on, respectively, particularly when the part is being designed having walls of generally uniform thickness. 
     Suitable control means may be provided for automating the manufacturing process, and suitable surface resistivity meters may be incorporated in the manufacturing system to check that sufficient charge is being applied to the substrate before the mold injection. 
     In a variation of the molding process, a substrate may be provided comprising a metallic layer and an outer facing non-conducting layer bonded thereto, similar to substrate  50 , mutatis mutandis, but without an inner non-conducting layer. In such a case, the molten material comes into contact directly with the metallic layer, which may optionally be pre-treated as desired, for example having a coating of primer, adhesive, paint, etc., possessing the same during the injection process. In a variation of this process, where the metallic layer may be in the form of a net or mesh, or otherwise comprises openings exposing parts of the outer facing non-conducting layer to the molten material, these parts may be possessed by the molten material during the injection process. 
     The base  23 , which may be fabricated separately, for example also via injection molding, may be mounted onto workpiece  20 ′ to complete part  20 . In other embodiments, the intermediate workpiece is the final part. 
     Referring to  FIG. 4 , the process for manufacturing part  30  is similar to that described for part  20 , mutatis mutandis, with the following main differences. The substrate  50  is now disc-shaped, and the robotic arm  170  comprises an end-of-arm tool in the form of a suction head  174 ′ comprising suction ports  173 ′ and adapted for transporting and positioning the substrate in substantially flat form, rather than in a looped cylindrical form, into cavity  132 ′ of female mold part  110 ′, having been charged with static electricity via charger  190 . The earthed mold part  110 ′ holds at least a part of the substrate in abutting contact with mold surface  122 ′, which corresponds to surface  31  of the part  30 , the substrate  50  having been released from the robotic arm. Subsequently, the mold  100 ′ is closed and material  199  is injected into the mold cavity via one or more outlets  145 ′, pushing the substrate  50  into the cavity  132 ′ such that the outer surface  51  is in substantially full abutting contact with surface  132 ′. In particular the central portion of the substrate  50  may be deformed to a mild convex form, and the circular edge  57  of the substrate  50  may be deformed to press against the generally cylindrical edge  123 ′ of surface  122 ′, to conform to such a particular form illustrated for the mold surface in  FIG. 4 . 
     According to another aspect of the invention, one or more free edges of the substrate  50  are visually hidden to some extent, and the manufactured item, for example corresponding parts  20 ,  30  are configured for this. This feature may help in effectively hiding from view possible misalignments between the substrate  50  and the desired or nominal position that it is intended to assume with respect to the particular corresponding molded part. 
     For example, referring to  FIG. 5 , the rim  25  of part  20  comprises a radially extending annular flange  61  having a circumferential lip  63  depending therefrom in the axial direction towards the base  23 , defining an annular recess  62  between surface  21  and the lip  63  of depth t. Depth t is dimensionally greater, axially, than the gap g that is expected to be formed between edge  59  and the flange  61 , including statistically acceptable variations in dimension g. Similarly, any overshoot of edge  58  into the recess and onto the underside of flange  61  will also not be readily apparent when viewing surface  21 . Thus, when viewing part  20 , edge  58  is effectively hidden from view via lip  63 . By means of non-limiting example, depth t may be between about 0.3 to 13 mm, more particularly between about 1 mm and about 5 mm, and more particularly between about 2 mm and about 4 mm. 
     In another example, and referring to  FIG. 6 , an annular recess  66  is provided between the surface  31  and the rim  33  of the lid  30 . The recess  66  is of a depth such that allows the edge  57  or disc-shaped substrate  50  to be deformed into the recess to a variable depth during the injection molding process, even allowing parts of the edge  57  to overshoot the bottom of the recess  66 . The edge  57  is effectively hidden from view, or at least not generally readily discernible, when viewing surface  31  from any one of a variety of directions, being effectively hidden by the rim  33 . By means of non-limiting example, the depth of annular recess  66  may be between about 0.3 mm and about 5 mm, and more particularly between about 0.5 mm or about 1 mm and about 4 mm. 
     In yet another example, and referring to  FIG. 7 , the visual effect of a small mismatch in alignment between the substrate and manufactured part may also be effectively minimized by providing a stepped configuration at some of the visually exposed edges of the substrate with respect to the part. In this figure, a container  200  according to another embodiment of the invention is illustrated, comprising a box-like bottom part  220  and a lid part  230 . The lid part  230  comprises a generally flat top  241  and sides  242  depending therefrom, with a rim  233  circumscribing the free edges of the sides  242 . Corner portions  244  each comprise generally mutually orthogonal corner sides  252  and a corner top  251 , which are protruding outwardly with respect to the corresponding sides  242  and top  241 , respectively, by a step Q. By means of non-limiting example, the step Q may be between about 0.2 mm and about 5 mm, typically more particularly between about 0.3 mm or 0.5 mm an about 1 mm or 2 mm or 3 mm. 
     The visually exposed surface  231  of interest in this example is the top  241  and sides  242 , but not including the corner portions  244  or rim  233 . Accordingly, a substrate may be possessed in situ within a mold during the molding process for the lid part  230 , for example in a similar manner to that described above for other embodiments of the invention mutatis mutandis. In this case, though, the substrate may be of a generally cruciform planform. Small misalignments between the concave corners of the cruciform substrate and the edges of corner portions  244  may result in some of the edges of the substrate overrunning onto steps Q or not reaching steps Q, and the presence of the step Q itself can aid to mask this misalignment. A similar effect may be obtained between the other edges of the substrate and the rim  233 , and thus a recess (not shown) may be provided in rim  233  where the sides  242  and/or  252  meet the rim  233  for obscuring any misalignments between the corresponding edges of the substrate and the rim  233 . The rim recess may be provided in addition to, or instead of, the stepped corner portions  244 . 
     This aspect of the invention may be applied to substrates having a metallic appearance and comprising an electrically conducting material therein, for example substrate  50 , or alternatively with fully non-conducting substrates, including printed artwork, patterns etc., mutatis mutandis, and using the method of injection molding according to the invention, or any other suitable injection molding method in which a substrate is placed in the mold before injection molding, mutatis mutandis. 
     In the method claims that follow, alphanumeric characters and Roman numerals used to designate claim steps are provided for convenience only and do not imply any particular order of performing the steps. 
     Finally, it should be noted that the word “comprising” as used throughout the appended claims is to be interpreted to mean “including but not limited to”.