Patent ID: 6843954

Claim:
A process for injection-molding an article with a fluid channel formed therein to provide strength and structural integrity, comprising the steps of: providing a mold defining a mold cavity; providing at least first and second molten resin streams within the mold cavity wherein each resin stream has a flow front; causing the flow fronts of the resin streams to meet at a longitudinal point in the mold cavity and form a first layer of solidified resin on the peripheral surface of the mold, the first layer having at least one knit line at the longitudinal point where the resin fronts meet; and introducing a fluid into either or both of the molten resin streams in the mold to form a fluid channel and a second layer, the second layer between the first layer and the fluid channel, the second layer devoid of a knit line at the longitudinal point where the resin fronts 15 meet.