Patent ID: 8790562

Claim:
A method of making a molding utilizing a dynamic seal in a molding apparatus comprising: providing a molding apparatus comprising upper and lower mold halves, one of the upper and lower mold halves having a molding cavity, a seal cavity and at least one movable mold portion formed therein; providing a preformed, integral dynamic seal comprising a base portion, an intermediate seal portion, a straight arm portion and a flexible arm portion, each arm portion extending from the intermediate seal portion, but in different directions; placing the base portion of the dynamic seal into at least a portion of the seal cavity in a manner so as to prevent its movement within, or its removal from, the seal cavity, and allowing the intermediate seal portion and flexible arm portions to extend out of the seal cavity into the molding cavity; placing a sheet of a substrate material into the molding cavity, at least a portion of the peripheral portion of the substrate being proximate the dynamic seal, such that the straight arm portion is in sealing contact with a major surface of the sheet of substrate material, and the flexible arm portion is proximate at least a portion of the peripheral edge of the sheet of substrate material; closing the upper and lower mold halves, which action causes the at least one moveable mold portion to contact the flexible arm portion, moving the flexible arm portion in an arc up to 15° and sealingly pressing the flexible arm against the peripheral edge of the sheet of substrate material; injecting a liquid polymeric material into the mold cavity where it is allowed to flow at least up to the edge of the peripheral edge of the sheet of substrate material, but is prevented from flowing past where the flexible arm portion is in sealing contact with the peripheral edge of the sheet of substrate material; allowing a sufficient time for the polymeric material to cure; opening the mold halves, thus disengaging the movable mold portion from sealing contact with the flexible arm of the dynamic seal, and allowing the flexible arm portion to move out of sealing contact with the portion of the peripheral edge of the substrate material; and removing the substrate with polymeric material molded thereon from the molding apparatus.