Selectively controlling in-mold coating flow including inlet flow control and removable containment flange

Description of equivalent WO 03092979 A1

SELECTIVELY CONTROLLING IN-MOLD COATING

FLOW INCLUDING INLET FLOW CONTROL

AND REMOVABLE CONTAINMENT FLANGE

Field of the Invention

The present invention relates to a method for coating a molded article or thermoplastic substrate with an in-mold composition, wherein the flow and thus the thickness of the in-mold composition onto the substrate can be selectively controlled. Importantly, desired areas of molded articles can be preferentially coated with in-mold coating compositions by controlling the thickness or depth of various sections of the substrate. Advantageously, the method of the present invention can be utilized to mold articles of relatively complex shape or design which have an in-mold coating thereon having a uniform or desired appearance. In one embodiment of the present invention, a molded article is provided with an area of increased relative thickness at the location of in-mold coating injection in order to encourage or promote in-mold coating flow. The area of increased relative thickness is readily compressible by the in-mold coating and desired controlled flow of in-mold coating across the surface of the substrate can be achieved. In another embodiment of the present invention, a molded article or substrate is provided with at least one runner section or preferred flow channel to promote in-mold coating flow over the surface of a substrate.

Still another embodiment of the present invention involves providing a molded article or substrate with an in-mold coating containment flange which acts as a barrier and prevents the in-mold coating from leaking or seeping off of the desired surface and out of the mold cavity. The in-mold coating containment flange extends substantially completely around the perimeter of a molded substrate surface where the in-mold coating has been applied thereto.

In still yet another embodiment, the present invention relates to an in-mold coated article or substrate having an easily removable defined flash edge or flange for containment of in-mold coating. Without a flash edge component, uncured in- mold coating is often lost from the intended surface of a substrate to be coated. The substrate provided with a flexible flash edge or containment flange serves as a barrier that prevents uncured or fluid in-mold coating from contaminating both mold surfaces and substrate surfaces desired to be maintained free of coating. After the molding and coating has been accomplished, the flash edge can be easily removed as by hand with little effort by flexing, leaving a coated article of predetermined dimensions.

Description of the Prior Art Molded thermoplastic and thermoset articles, such as those made from polyolefins, polycarbonate, polyester, polyethylene, polypropylene, polystyrene and polyurethanes, are utilized in numerous applications including those for the automotive, marine, recreation, construction, office products, and outdoor equipment industries. For example, automotive industry applications include body panels, wheel covers, bumpers, head and tail lamps, fenders, hoods, and dashboards.

Use of the molded articles is not without problem, as the surface quality may not meet required standards, such as durability, chemical resistance, and weather resistance. In many instances, the molded thermoplastic articles may need to be coated to satisfy the above-noted requirements or to facilitate paint adhesion.

Countless methods have been developed to apply various coatings to the molded articles to improve the surface characteristics thereof. Previously, molded work pieces were formed in a mold, the molded product removed, and a coating was then applied on the surface of the molded work piece by a coating process, such as a surface treatment, primer coating, top coating, painting, etc. Hence the foregoing methods required at least one additional step to achieve a finished surface on a work piece, i.e. treating the surface of the pre- formed work piece prior to applying a paint or coating. These methods required additional steps and increased costs of preparing the molded work piece surface.

It became desirable, therefore, to have a method by which a coating could be applied to a work piece in the mold, resulting in a coated work piece the surface of which would be finished and suitable for use as is in an end use application, or which would require less or no surface preparation treatment than heretofore utilized.

The application of in-mold coatings (IMC) to thermoplastic or thermoset materials to provide generally smooth surfaces, improve durability and other surface properties, and to reduce or eliminate substrate porosity is known. A number of in-mold coating methods have been employed for applying coatings, in compression molding methods or injection molding methods employing molding materials of thermosetting resins, such as SMC (sheet molding compound) and BMC (bulk molding compound) (e.g., U.S. Pat. Nos. 4,076,788; 4,081,578; 4,331 ,735; 4,366, 109; and 4,668,460).

Heretofore, the in-mold coatings which have been applied to molded articles typically covered the entire surface of the article. The coverage of the coating was controlled by only the amount of coating applied, such as in the case of an undershot, or the physical boundaries of the mold cavity. International Application Number PCT/CA01/00534 relates to a method of molding a panel or product having an in-mold coating applied thereto. The molded part has a flange which extends about the periphery of the molded part. The flange includes a rigid notch having a depth of at least 1 mm, and an outer raised portion or racetrack outside of the notch which is 3 mm thick. Due to the thickness of the notch, the flange is stiff, rigid and not removable by hand. Accordingly, the part includes a coated surface on at least a partially uncoated outer surface which is unsightly.

Summary of the Invention An improved method for applying in-mold coatings has been developed, whereby molded articles can be preferentially coated in a desired area, and depth of coating can be regulated by selectively controlling the thickness of sections of the article.

The present invention relates to a method for preferentially in-mold coating a molded article or substrate in at least one predetermined area based upon the thickness or depth of the article. A first composition is molded into an article or substrate in a mold, preferably by injection molding techniques known in the art. A second composition is applied to the substrate in-mold, wherein the second composition is directed to at least one predetermined area of the substrate based on the compressibility thereof.

Molded substrates often have complex designs or configurations and, heretofore it has been difficult or impossible to produce an in-mold coated article which has been properly or fully coated to desired specifications. Advantageously, it has been found that the flow of in-mold coating over an article can be effectively controlled, whereby the coating can be channeled or routed so that the coating on the substrate surface conforms to design specifications. The in-mold coatings are preferably channeled by providing the 5 substrate with areas of varying thickness or depth below the surface to be coated. It has been found that substrate areas of greater depth promote in-mold coating flow relative to less thick areas. The present invention also teaches a method for controlling the thickness of an in-mold coating on a substrate.

The present invention provides a method for producing molded articles with L0 coatings in predetermined areas which are suitable for use as-is in an end use application or which require minimal or no surface post-treatment.

In one embodiment, a substrate is provided with an easily removable flash edge or flange. The flash edge prevents in-mold coating loss from the intended substrate surface. The flash edge thus offers cost savings by conserving the L5 amount of in-mold coating utilized in a molding operation. Contamination of uncoated part surfaces as well as mold surfaces is also prevented. The flash edge can be easily removed by hand or simple tools after the coating process, leaving a coated substrate having desired dimensions.

A further object of the present invention is to eliminate the need of applying 20 additional paint or other surface treatment coatings to a surface of a pre-formed work piece.

Yet another object of the present invention is to provide a work piece having an appearance in-mold coating thereon, which has paint-like properties, such as high gloss, hardness, good adhesion and good weatherability. 25 A further object of the present invention is to provide a work piece having an in-mold coating thereon, which has good flow and coverage during molding, good adhesion, uniform color, durability, weather resistance, good surface qualities, and good paintability.

In one embodiment of the present invention, a molded article is provided with 0 an area of increased relative thickness at the location of in-mold coating injection in order to encourage or promote in-mold coating flow.

In yet another embodiment of the present invention, a molded article or substrate is provided with at least one runner section or preferred flow channel to promote in-mold coating flow over the surface of a substrate. Still another embodiment of the present invention involves providing a molded article or substrate with an in-mold coating containment flange which acts as a barrier and prevents the in-mold coating from leaking or seeping out of the mold cavity. The in-mold coating containment flange extends substantially completely around the perimeter of a coated molded substrate surface.

Brief Description of the Drawings

The invention may take physical form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention.

FIG. 1 is a side view of one embodiment of a molding apparatus suitable for practicing the method of the present invention.

FIG. 2 is a cross section through a vertical elevation of a mold cavity. FIG. 3 is a top view of a molded substrate prior to being coated with an in- mold coating. The substrate is shown having an area of increased thickness in order to promote and/or channel in-mold coating flow.

FIG. 4 is a front view of the substrate shown in FIG. 3.

FIG. 5 is a back view of the substrate shown in FIG. 3, wherein areas of varying depth are distinctly shown.

FIG. 6 is a side view of a molded door panel. The door panel is provided with areas of varying depth in order to channel in-mold coating flow over the surface so that the same is coated in desired areas in order to meet a predetermined standard. FIG. 7 is the substrate of FIG. 4 having an in-mold coating on a show surface thereof.

FIG. 8 is the substrate of FIG. 4 having an in-mold coating located substantially only in a runner section of the show surface.

FIG. 9 is a front elevation view of a substantially flat molded plaque with a substantially flat show surface. The location of runner sections and thickness are shown for the benefit of the viewer.

FIG. 10 is a front view of a molded substrate with areas of varying thickness illustrated. FIG. 11A is a front view of a molded substrate containing a readily compressible area at the location where an in-mold coating is to be injected onto the surface of the substrate.

FIG. 11 B is a cross-sectional side view of FIG. 11 B through lines 11 B-11 B and illustrates a compressible area below the point of in-mold coating injection.

FIG. 11C is a front view of the molded substrate of FIG. 11A wherein the substrate has been coated with an in-mold coating.

FIG. 12A is a front view of a molded substrate containing a readily compressible area at the location wherein an in-mold coating is to be injected onto the surface of the substrate.

FIG. 12B is a cross-sectional side view of the plaque shown in FIG. 12A while the molded substrate is still in a mold cavity and an in-mold coating has been applied to the show surface of the substrate.

FIG. 12C is the front view of the in-mold coated article shown in FIG. 12B. FIG. 13 is a plan view of a substrate having a removable, flexible, in-mold coating containment flange.

FIG. 14 is a cross section of FIG. 13 through 14-14 illustrating a preferred embodiment of a removable in-mold coating containment flange.

FIGS. 15A through 15D are cross sectional illustrations of molded substrates having removable in-mold coating containment flanges of various configurations.

FIG. 16 is a plan view of a substrate having a removable, in-mold coating containment flange extending completely around the perimeter of the substrate show surface.

FIG. 17A is a plan view of a substrate having a removable in-mold coating containment flange on the show surface of as well as on the perimeter in order to contain the in-mold coating to a predetermined area of the show surface.

FIG. 17B is a cross sectional view of a FIG. 17A through 17A-17A.

Detailed Description of the Preferred Embodiments The present invention relates to producing a molded article or substrate having a coating bonded thereto. The coating is present on the surface of the substrate in a predetermined area or areas. In-mold coating thickness can also be controlled by the method of the present invention. More particularly, the method of the present invention provides a process for controlling the flow of a liquid in-mold coating so that it can be channeled or routed on a substrate to result in a coating having a uniform thickness or appearance on a large or complex shape. The in- mold coating can be channeled to coat an entire surface of a substrate or only selected areas thereof. 5 The method of the present invention can generally be practiced on any molding apparatus such as injection molders capable of producing a molded article or substrate of a first composition and then coating the article or substrate with a second composition, i.e., an in-mold coating.

Making reference now to the drawings wherein like numerals indicate like or

L0 corresponding parts throughout the several figures, a molding apparatus suitable for the practice of the present invention is shown in FIG. 1 , and is generally designated 10. Molding apparatus 10 includes a first mold half 20 which preferably remains in a stationary or fixed position relative to a second moveable mold half 30. FIG. 1 shows the mold halves in an open position. The first mold half and second

L5 mold half are adapted to mate, or abut, thereby forming a mold cavity 40 therebetween as shown in at least FIG. 2. The mold halves mate along surfaces 24 and 34 (FIG. 1) when the molding apparatus is in the closed position, forming a parting line 42 (FIG. 2) therebetween.

The moveable mold half 30 reciprocates generally along a horizontal axis

20 relative to the first or fixed mold half 20 by action of a clamping mechanism 70 with a clamp actuator 72 such as through a hydraulic, mechanical, or electrical actuator as known in the art. The clamping pressure exerted by the clamping mechanism 70 should have an operating pressure in excess of the pressures generated or exerted by the first composition injector and the second composition injector. The pressure 5 exerted by the clamping mechanism ranges generally from about 2,000 pounds per square inch (psi) (138 bar) to about 15,000 psi (1033 bar), preferably from about 4,000 psi (276 bar) to about 12,000 psi (827 bar), and more preferably from about 6,000 psi (413 bar) to about 10,000 psi (689 bar) of mold surface.

In FIG. 2, the mold halves 20 and 30 are shown in a closed position, abutted 0 or mated along parting line 42 at face surfaces 24 and 34. As illustrated, the mold cavity is shown in cross section. It is readily understood by those skilled in the art that the design of the cavity can vary greatly in size and shape according to the end product to be molded. The mold cavity generally has a first surface 44 on the first mold half, upon which a show surface of an article will be formed, and a corresponding back side or opposite second surface 46 on the second mold half. The mold cavity also contains separate orifices to allow the first and second composition injectors to inject their respective compositions thereinto. The location of the injectors and injection orifices thereof can vary from apparatus to apparatus, and part to part, and can be based on factors such as efficiency, functionality, or desire of the mold designer.

As shown in FIG. 1 , the first composition injector 50 is a typical injection molding apparatus which is well know to those of ordinary skill in the art and is capable of injecting a thermoplastic or thermosetting composition, generally a resin or polymer, into the mold cavity. The first composition injector is shown in a "backed off' position, but it is readily understood that the same can be moved to a horizontal direction so that nozzle or resin outlet 58 mates with mold half 20 and can inject into mold cavity 40. For purposes of illustration only, the first composition injector in FIG. 1 is a reciprocating-screw machine wherein a first composition can be placed in hopper 52 and rotating screw 56 moves the composition through the heated extruder barrel 54, wherein the material is heated above its melting point. As the material collects in the end of the barrel, the screw acts as an injection ram and forces it through the nozzle 58 into the mold cavity 40. The nozzle generally has a non-return valve at the nozzle or screw tip to prevent the backflow of material into the screw.

The first composition injector is not meant to be limited to the embodiment shown in FIG. 1 but can be any apparatus capable of injecting a thermoplastic composition into the mold cavity. Suitable injection molding machines are available from Cincinnati- Milacron, Battenfeld, Engel, Husky, Boy and others. The present invention for selectively controlling the flow of in-mold coatings can be practiced on generally any thermoplastic substrates which can be injection molded. Suitable thermoplastic substrates, include but are not limited to polyethylene terephthalate (PET), nylon, acrylonitrile butadiene styrene (ABS), polystyrene, fiber reinforced plastics, glass filled polymers, polyacrylate, polyester, polyphenylene sulfide, polysulfone, polyurethane, styrene-acrylonitrile, polycarbonate, acrylic, acetal, polyolefins such as polyethylene, polypropylene, and polyvinyl chloride (PVC). The foregoing list is not meant to be exhaustive but only illustrative of the various materials useful in the practice of the invention. It has been found that a surface of the substrate can be selectively coated with in-mold coatings in predetermined areas by controlling or modifying the thickness or depth of the substrate. When utilized in the present invention, thickness or depth is defined as a distance, girth, or dimension from one surface to

5 the opposite surface of the substrate. The method of the present invention is generally concerned with the depth between two surfaces, the first being a surface to which an in-mold coating is selectively directed or applied, commonly referred to as a show or appearance surface, and the second being a back surface that is substantially the opposite side of the substrate. The in-mold coating may but does

0 not necessarily cover the entire show surface. For example, in FIG. 3 thickness refers to the distance from show surface 82 of a substrate to the backside or opposite surface 84. As shown in FIG. 3, the thickness between the show surface and back side of the substrate can vary.

Each substrate of the present invention inherently has a compressibility

.5 factor or percentage, wherein at a given temperature each specific substrate is compressible to a certain calculable percentage. Therefore, even though a molded article or substrate has a single compressibility ratio, a first area of a substrate which is thicker relative to a second area of the substrate will be able to compress a greater thickness or distance than the second substrate. For example, substrate

>0 "A" has a compressibility ratio of 20 percent at a certain temperature. Therefore, a portion of substrate "A" which has a thickness of 2.0 cm can compress 0.4 cm, whereas a portion of the substrate which has a thickness of 1.0 cm can only compress 0.2 cm at the given temperature.

The above described substrate compressibility can be utilized to selectively

>5 coat predetermined areas of a substrate. Substrate compressibility can also be utilized to effectively direct the flow of an in-mold coating into certain areas or pathways of a substrate.

In-mold coatings can be applied to a substrate in numerous ways well known to those of ordinary skill in the art. The present invention is not meant to be limited

50 to the following example. As shown in FIG. 2, an in-mold coating or second composition injector 60 has a nozzle 62 which is located on the molding apparatus in a suitable location such as on mold half 30. A first quantity of a first composition 80 is injected into a mold cavity to a desired predetermined level, forming a substrate, work piece, or article, such as plaque 100 shown in the views of FIGS. 3- 5. As shown in FIG. 3, the substrate has at least a show surface 82 and a back side 84. An in-mold coating composition 90 is then injected into the mold cavity from in-mold coating injector 60. The in-mold coating is injected through at least one nozzle 62 onto the show surface side of the substrate at a location such as 104

5 on tab 102 as shown in FIG. 4.

It is important to note that the mold is not opened or undamped before and/or during in-mold coating application, that is, the mold halves maintain a parting line and generally remain a substantially fixed distance from each other while both the first and second compositions are injected into the mold cavity as

0 described herein. Thus, the mold cavity defined by the mold halves has a fixed volume that generally remains constant while both the first and second compositions are injected thereinto.

The liquid in-mold coating composition spreads out, disperses, or radiates from the point of injection 104 onto the show surface of the substrate. The point of

5 injection of the in-mold coating onto the substrate will depend on the location of the in-mold coating injector and nozzle thereof in the molding apparatus. Accordingly, the point of injection of the in-mold coating can be located substantially anywhere on the substrate and is not limited to the locations shown in the drawings of the present invention. The in-mold coating cures on the substrate sometime after

»0 injection as known in the art. The cure is optionally heat activated, from sources including but not limited to the molded substrate or the mold itself.

One embodiment of the present invention relates to a method for directing or channeling the flow of an in-mold coating on a substrate. Unexpectedly, it has been found that substrate compressibility can be utilized to direct in-mold coating

25 flow for in-mold coating systems which are conducted "closed clamp", wherein the mold halves remain abutted or closed at least during the time between injection of a first composition and an in-mold coating composition. That is, the parting line between the mold halves is not separated during the molding operation in which an in-mold coated substrate is produced. When mold halves 20, 30 are closed or 0 joined, a mold cavity 40 is formed therebetween. The mold cavity has a configuration with a specific defined volume. A predetermined amount of a first composition which will produce a desired substrate is injected into the mold cavity. By the term predetermined, it is understood by one of ordinary skill in the art that through the control of variables of the molding process, a calculated amount of material that will produce a desired substrate can be experimentally determined. After the first composition has been injected into the mold cavity and has cooled below the melt point or otherwise reached a temperature sufficient to accept or support an in-mold coating, a predetermined amount of in-mold coating is injected 5 from injector unit 60 through at least one nozzle onto an injection point of the substrate, preferably on a show surface thereof. The coating is injected at a pressure that ranges generally from about 500 psi (34 bar) to about 5,000 psi (345 bar), preferably from about 1 ,000 psi (69 bar) to about 4,500 psi (310 bar), and more preferably from about 2,000 psi (138 bar) to about 4,000 psi (276 bar). The

L0 injection pressure promotes the spread of the in-mold coating away from the nozzle. The in-mold coating spreads from the nozzle between a mold surface and a surface of the substrate.

Unexpectedly, it has been found that by varying the thickness or depth of the resin of the substrate below the surface to be coated, the in-mold coating can be

L5 routed to preferred areas of the substrate, and contained therein, if desired. For example, if a mold cavity is designed so that a substrate has a constant thickness under an area to be in-mold coated, the in-mold coating will spread out from the location of injection in a substantially radial, even, or constant manner. Under the same relative conditions, if a substrate is formed having areas which vary in

20 thickness under the surface area to be coated, the in-mold coating can be channeled to flow in area(s) of greater relative thickness. Thus, the depth of the coating can also vary on the coated surface. It has been demonstrated, as stated hereinabove, that the compressibility of the substrate allows a substrate area having a greater depth relative to a second area to compress more and better

25 accommodate in-mold coating flow and promote migration thereof.

In one embodiment of the present invention, a substrate is provided with an area or section of increased thickness around the point or location where the in- mold coating is injected onto the substrate in order to promote in-mold coating flow. By increased thickness, it is to be understood that the thickness of the substrate 0 around the in-mold coating injection location is greater than at least one other area or section of the substrate. As shown in FIG. 5, plaque 100 is shown with a tab area 110 at a location of in-mold coating injection. The tab area thickness can be varied to enhance channeling of the in-mold coating. Tab section 104 in FIG. 4 includes a thin section or in-mold coating containment tab flange 102 which prevents the in-mold coating from flowing out of the mold cavity. The concept of the containment flange will be further explained hereinbelow. The relatively thick tab area promotes in-mold coating flow from the in-mold coating nozzle onto the show surface 80 of the substrate. The in-mold coating will tend to avoid the tab or

5 other substrate sections of minimal or lesser thickness.

The in-mold coating is injected into the mold cavity after the substrate has cooled from a molten state and achieved a desired modulus or rigidified sufficiently to be capable of accepting the coating on a surface thereof. When the coating is injected into the mold, the coating flows or spreads between the mold cavity surface

10 and adjacent substrate surface at least by compressing the substrate utilizing compressibility of the substrate as defined hereinabove. In practice the in-mold coating can be injected substantially anywhere on the surface of the substrate, whether on the front (show) side or back side thereof. For example, the in-mold coating can be injected on a center portion of a substrate surface at 310 as shown

L5 in FIG. 11A, or a corner of a substrate surface at 410 as shown in FIG. 12A.

Typically, the in-mold coating will be injected at a location on a molded substrate which is inconspicuous or will not be visible when the article is used. Alternatively, the in-mold coating can be injected onto the substrate at a location which can later be removed or cut away from another portion of the substrate. For

I0 example, if desired, the in-mold coating injection area at tab 110 of FIGS. 4 and 5 can be cut away where it connects to the main portion of the molded substrate, leaving a substantially square in-mold coated article.

It has been found that in-mold coating flow can be promoted or enhanced by creating an area of increased relative thickness or a compressible zone on the

5 substrate at the location of in-mold coating injection. FIGS. 11A through 11C illustrate a molded substrate 300 including a compression differential to promote in- mold coating flow on a substrate. FIG. 11 A is a front view of substrate 300 wherein a containment flange 330 as described within the specification can be utilized to confine the in-mold coating to the show surface 302 of the substrate. In this

0 embodiment, the in-mold coating is injected onto the injection inlet area 310 of the substrate in the mold cavity during a molding and in-mold coating cycle as described within the specification and well known to those of ordinary skill in the art. Area of substrate injection 312 is also illustrated in phantom as the substrate has been injected from the side opposite the show surface 304 to hide any flow lines or undesirable edges which may be present after a sprue is removed.

This area of increased thickness forms a "flow zone" which is selectively used to control the flow and thus the thickness and surface area of the coating. For 5 example, for an area of increased relative thickness which has a corresponding increased area of compressibility, the flow zone promotes the flow of the coating from the flow zone to the contiguous surface of the substrate for the area adjacent the flow zone which has a relatively thinner cross section than the flow zone. This flow zone is also adjacent the injection site for the coating. The flow zone is distinct

.0 from other complex cross sections having increased thickness as may occur from reinforcing struts or similar structural details in so far as the flow zone is designed for selectively controlling the flow of the coating by providing a channel of increased (or decreased) compressibility. It should be understood however, that these areas of increased (or decreased) thickness may also serve as flow zones. Likewise, the

L5 fiow zone may comprise an area of decreased compressibility such as occurs for a thinner cross section area like a peripheral flange. In this case, the flow zone acts as containment zone for the coating. Further in this case, the flow zone does not need to be adjacent, and in fact probably will be remote rather than adjacent to the injection site.

10 FIG. 11 B is a cross-sectional side view through 11 B-11 B of the molded substrate of FIG. 11 A. The show surface 302 and back surface 304 have a variable distance or thickness therebetween. Sprue 314 is formed during the substrate injection molding step. The area behind in-mold coating injection inlet area 310 is provided with area 308 which has a greater thickness than substrate 5 regions 306 in order to promote in-mold coating flow. Area 308 has a thicker section or greatest depth at its central portion where the in-mold coating is injected onto the show surface. The thickness of the substrate tapers down from the in- mold coating injection inlet area 310 and reaches a relatively constant depth in substrate section 306. The relative depth or thickness provided to area 308 0 provides a readily compressible area for the in-mold coating and promotes flow out to other desired areas of the show surface. As shown in FIG. 11C, the in-mold coating 320 completely covers substrate 300 show surface 302. Alternatively, if desired, the substrate can contain other compression differential zones such as a mold runner described herein and can be coated in preselected areas utilizing substrate compressibility.

FIGS. 12A-12C further illustrate the use of substrate compressibility to create a compression differential which promotes in-mold coating flow at an in-mold 5 coating injection inlet area. FIG. 12A shows molded substrate 400 with show surface 402 and in-mold coating containment flange 430. The in-mold coating is to be injected at in-mold coating inlet area 410 during an in-mold coating process phase or step in a mold cavity. The substrate was injected into the mold cavity at a location behind area 412. FIG. 12B is a partial cross section of plaque 400 situated

L0 in a mold cavity 440 between mold halves 442 and 444. The molded substrate has been coated with in-mold coating 420 from in-mold coating injection device 422 through in-mold coating inlet channel 424 via a nozzle at in-mold coating inlet area 410. The mold parting line 460 is also illustrated. The in-mold coating is injected onto the substrate at area 408 which has an increased thickness when compared

15 to the other portions of the substrate including area 406. The in-mold coating can more easily compress the substrate in area 408 as compared to area 406 due to the increased thickness thereof. FIG. 12C illustrates the front view of in-mold coated substrate 400 show surface 402 having in-mold coating 420 thereon.

The substrate has a thickness ratio at the location of in-mold coating 0 injection (such as 310 in FIG. 11 A) when compared to another portion of the substrate intended to be coated generally from about 1.10:1 or about 1.25:1 to about 10:1 , desirably from about 1.25:1 to about 2:1 , and preferably from about 1.3:1 to about 1.4:1 or about 1.5:1.

In order to promote smooth, even flow of the in-mold coating across the 5 intended, preferably the show surface of the substrate, a smooth or substantially constant transition is made from the location of in-mold coating injection to the other substrate areas as shown in FIGS. 11 B and 12B. The transition zone can also be considered a taper or ramp. Of course, as stated herein other features such as runner sections and coating containment flanges can also be incorporated into the 0 substrate to control or promote in-mold coating flow.

In a further embodiment of the present invention, a substrate is provided with at least one "runner" section, preferential flow channel, or area to promote in-mold coating flow on a substrate. A runner section is an area which is relatively thicker than another area adjacent thereto, wherein the in-mold coating can be preferably routed to flow. Advantageously, runner sections can be provided on substrates of complex design or which were previously difficult to coat. A runner section generally is located in an area on the substrate beginning in the region of the point of injection of the in-mold coating and extending away therefrom to a predetermined point or terminus on the substrate. For example, FIG. 5 has a runner section 106 extending from and including the tab area to substantially the bottom end 107 of the plaque. FIG. 6 shows a door panel having three runner sections 120. By providing a substrate with at least one runner section, in-mold coatings can be effectively routed or channeled to cover desired areas of a substrate.

Depending on the amount of in-mold coating injected into the mold cavity, the show surface substrate having a runner section can be completely coated or coated only in certain areas or sections such as the runner areas. The amount of coating applied and thickness thereof can vary from part to part. The depth of the runner section can vary depending on the substrate to be coated and design specifications. A substrate can have a runner section extending from an area of in-mold coating injection which is so relatively thick that all of the in- mold coating application to the substrate surface will substantially remain in the runner section. Therefore, as can be imagined, many unique effects can be created by utilizing runner sections. Frequently, it is desirable to completely coat the show surface with an in-mold coating. It is often difficult to coat a substrate having a complex or detailed shape. Runner sections can be used to effectively in- mold coat these substrates by channeling in-mold coating to the previously hard to coat areas. For example, a runner section can be utilized to channel a coating to a distal part of a substrate surface. The runner section thickness can be gradually decreased such as in a direction away from the point of injection as needed, or even separated or divided into more than one runner section to accomplish a desired effect or coating.

In yet another embodiment of the present invention, a molded substrate or article is provided with an in-mold coating containment flange 130. As shown in at least FIG. 4, the coating containment flange preferably extends completely around the perimeter of a substrate, specifically plaque 100. Often, it is desirable to substantially coat the show surface of a substrate with an in-mold coating. The containment flange 130 acts a barrier and prevents the in-mold coating from leaking or seeping out of the mold cavity and potentially blowing out of the parting line between the mold halves.

As shown in at least FIG. 3, flange 130 is generally offset or formed in a plane below the plane of the show surface 82. Thus, the show surface has an edge or border 83 which transitions into flange 130. Show surface edge 83 drops off into a wall at an angle of about 90° relative to the show surface. Substrate wall 86 terminates at flange portion 130, wherein flange portion extends at an angle of about 90° in relation to wall 86. It is believed that the relatively sharp angles between show surface and flange 130 as well as the relative incompressibility of the thin flange act as a substantial barrier to coating flow, and thus prevent the coating from leaving the show surface. The flange generally has a thickness less than the thinnest portion or area of the substrate. As shown in FIG. 3, containment flange 130 is thinner than section 112, the relatively thinnest section of the substrate. The in-mold coating containment flange encompasses substantially the entire perimeter of a substrate surface that will be or is coated. The width may vary based on factors such as part design and wall stock dimensions. As stated above, the main purpose of the flange is to prevent the in-mold coating from leaving the target surface of the substrate and stopping the coating from gaining entrance to the mold parting line. As shown in FIG. 7, the in-mold coating 90 covers the entire show surface of the molded substrate. Due to the configuration of the molded substrate as well as other molding variables, the coating 90 does not cover or coat the containment flange 130. However, it is permissible for the in-mold coating to coat or partially coat the containment flange. Due to the design of the containment flange, generally less than about 10%, preferably less than 5%, and more preferably less than 1 % by weight of the in-mold coating injected in a single molding cycle covers or coats the containment flange. The containment flange is free of any other substrate material on the distal edge thereof. This is, there is no other substrate material or outer edge between the containment flange and the mold cavity parting line.

In still yet another embodiment of the present invention, an article with a separable, breakable, removable flash edge or containment flange is disclosed. Molded articles, parts, or substrates are most often constructed to conform to certain predetermined, definite tolerances. Frequently, the articles are designed to fit exactly or substantially exactly into an assembly or working arrangement of parts. Articles provided with an additional containment flange to contain a coating are often larger than specified manufacturing tolerances. Furthermore, often the 5 containment flange show surface is not coated with an in-mold coating, leaving the article with an undesirable appearance.

In most cases it is preferable to coat the entire show surface, i.e. usually one side, of an article with a paint or in-mold coating so that the substrate show surface is at least 80%, 90%, 95%, 99%, and preferably fully (100%) coated. While it is

.0 known in the art to coat an article surface with an in-mold coating, there is difficulty in keeping the uncured in-mold coating confined to the intended substrate target surface area. Frequently, the in-mold coating will flow, seep, or leak onto surrounding mold surfaces, such as around the parting line; the unintended back surfaces of the article which is not to be coated; and even out of the mold halves

L5 and mold itself. Another problem associated with coating leakage or seeping is that the coating may not become properly packed in the mold resulting in coated parts having dull, non glossy appearances, parts not having an even film build or adequate coating thickness, or parts not exhibiting the desired or required texture. Coating seepage onto ejector pins can cause binding and unworkability of the

20 molding apparatus. The described overflow is unacceptable as parts or articles can be ruined, and mold surfaces must be cleaned to remove coating buildup, costing both time and monetary expense.

The present invention prevents the aforementioned problems by providing an article having an in-mold coating containment flange or flash edge which is 5 flexible and thus easily removable, e.g. by hand after the article has been coated and the coating cured. The coated article with the removable containment edge removed can be used "as is", such as in an assembly. One advantage of the removable containment flange is that an article having the flange, which may only be partly coated and possibly unsightly, can be easily removed and discarded. 0 Moreover, a fully coated part of desired dimensions and exact standards can be produced. Labor and monetary savings are other advantages as coating containment is achieved, and waste is minimized. The removable containment flange potentially eliminates part painting operations, secondary handling, and shipping costs between a part molder and a painter. Often up to 75% of a part cost is in the painting thereof. The in-mold coated part with a removable containment flange alleviates these problems.

A molded article or substrate having a removable flexible in-mold coating containment flange is shown in FIG. 13 and designated 200. The substrate main or show surface 210 has an in-mold coating thereon. Due to the presence of the removable in-mold coating containment flange 220, the in-mold coating applied to the substrate is prevented from leaving the surface of the substrate and contaminating other mold surfaces or the back side of the molded article. FIG. 13 also illustrates substrate injection area 230 wherein the substrate was injected into the mold. In-mold coating injection area 240 shows the ingress area or point of origination of the in-mold coating which has spread across the show surface of the substrate therefrom.

As also shown in FIG. 13, the removable flange preferably extends completely around the periphery of the substrate main surface in order to contain the in-mold coating flow from leaving the main surface, with exception to the area around the in-mold coating injection area 240 which already includes a feature for in-mold coating containment. The removable flange of the present invention generally extends at least 50% or 75% around the periphery of the substrate main surface, desirably at least 85% or 90%, and preferably substantially completely or completely around the periphery of the substrate main surface. FIG. 16 shows a removable flange 220 extending completely around the periphery of the main surface of a substrate 200. In-mold coating injection inlet area 240 is also shown. The removable flange will extend less than the complete distance around the perimeter or periphery of the substrate main portion if some other in-mold coating containment feature is present or substantially no in-mold coating leakage or seeping occurs in the specific area.

The removable confinement or containment flange is located or formed on a substrate surface in an area or plane between the show surface edge or perimeter, i.e. surface to be coated, and a backside edge or perimeter of the part. No matter which embodiment or design of flange is utilized, each flange has a width and a depth or height. As shown in FIG. 14, the width A can be defined as the greatest distance the flange extends outward, or away from the substrate main body C at a location between a show surface D to be coated and the non-show surface E opposite therefrom. Depth B can be considered a depth or thickness measurement, which can vary along the width of the flange, with the greatest depth generally existing at the outermost portion of the flange. An important aspect of the present invention is that the flange has a very thin section located adjacent to, or in the vicinity of, the substrate which is readily breakable. 5 The removable flange can have numerous configurations, all of which can be easily removed by hand. Removing the confinement or containment edge is as simple as for example, removing a piece of a model from a model kit parts card wherein the flange only needs to be bent or flexed back and forth to break the leading edge thereof away from the edge of the part main surface. FIG. 14 shows

L0 a configuration having a cross section through FIG. 13 wherein the flange 220 formed as a wedge having a depth greater at its outer end portion than where the same contacts and removably connects to the substrate main body. In this embodiment, the removable containment flange is formed only on one side of the parting line 205. The angle between the vertical side surface of the substrate main

L5 body and the containment flange top surface can vary from about 10° to about 90°, and is preferably from about 15° to about 30°. FIG. 15A shows a cross section of a coated substrate 220 with in-mold coating 216 on substrate 215 and triangular flange 221. A rectangular flange 222 is shown in the configuration of FIG. 15B. Circular and semicircular flanges can also be utilized as shown in FIGS. 15C and

20 15D respectively. The flange can be almost any geometric shape or design such as an ellipse, teardrop, or taper, etc.

In order that the flange of the present invention is easily removable, the point of attachment of the flange to the substrate main portion should be sufficiently thin to be easily separated or broken away therefrom. The thickness of the flange is

25 dependent on the substrate composition being molded. Accordingly, the thickness of the flange at the point of attachment immediately adjacent to the substrate is less than about 0.70 mm, 0.60 mm or 0.50 mm, and ranges generally from about 0.25 mm to about 0.50 mm, desirably from about 0.075 mm to about 0.45 mm, and preferably from about 0.10 mm to about 0.40 mm. As shown in the drawings, the 0 thickness of the flange in a direction away from the point of attachment to the substrate main portion can increase to any desirable thickness, which is generally greater than the thickness at the point of attachment. The thickness should be suitable so that the removable containment flange can be grasped in order to bend or flex the same for removal thereof. The width of the flange from the substrate main portion to the peripheral edge of the removable containment flange is generally from about 1 or about 2 mm to about 10 mm, desirably from about 2.5 mm to about 8 mm, and preferably from about 3 to about 6 mm.

The removable in-mold containment flange can be formed into either or both 5 of the mold halves described hereinabove as by machining, milling operation, or the like as known to those of ordinary skill in the art. Typically, the flange is formed along one or both sides of parting line 205 of the mold as shown in at least FIG. 14. Due to the design of the containment flange and the substantial incompressibility of the containment flange at the thin or narrow point of attachment to the substrate

LO main portion, the in-mold coating is predominately forced to stop at the attachment point between the substrate main body and containment flange as shown in FIGS. 15A-15D. That is, a compression gradient is formed and the in-mold coating is able to flow across the relatively thick, compressible substrate main portion, but cannot substantially flow across the relatively thin incompressible containment flange edge

L5 which is attached to the substrate main portion.

The removable in-mold coating containment flange is not limited in design to only extending around the perimeter of the show or other surface. In a further embodiment, the removable in-mold coating containment flange may extend onto a show or other surface of a substrate to prevent in-mold coating flow onto

20 predetermined areas of the show or other surface. FIG. 17A illustrates a substrate 300 having a removable in-mold coating containment flange 320 extending across a portion of show surface D as well as around a portion of the perimeter of the substrate to contain in-mold coating 316 to a quadrant or predetermined area of show surface D.

25 FIG. 17B is a cross sectional view through 17B-17B of FIG. 17A. From this view it is clearly shown that in-mold coating 316 is contained in a predetermined portion of the show surface D by the removable in-mold coating containment flange 320. Accordingly, the removable in-mold coating containment flange of the present invention can be utilized in any area(s) or location(s) on any surface of a substrate 0 to preferentially coat predetermined portions thereof. Crisply defined coating boundaries or areas on a substrate can be created when a removable containment flange is utilized on a substrate, especially a show surface thereof. Many different surface aesthetic effects can be created utilizing containment flanges, especially removable ones. Obviously, more than one, i.e. any number, of containment flanges can be utilized on an article or substrate. The containment flange can be utilized to create any type of pattern, design, logo, lettering, insignia, etc. Different colored in-mold coatings can be incorporated in different areas of a substrate which have containment flange boundaries, thus allowing for shading, contrasting colors, special effects, etc.

The removable in-mold coating containment flanges can also be used on a substrate at an edge opening adjacent to a moveable mold section such as a slide or core which are well known to those of ordinary skill in the art. The removable flange will prevent or block the in-mold coating from leaking into the moveable core area and possibly binding the same.

The removable in-mold coating containment flange can be removed easily from its attachment point to the substrate leaving a coated substrate of a desired dimension. The thermoplastic flange can be removed preferably by hand by bending or flexing the flange at the connection point to the substrate. The containment flange snaps away or disengages from the rest of the substrate leaving a crisp clean edge. Although not necessary, the containment flange can be also removed with tools such as a cutting edge, hot edge tools, water jet, buffer, sander, router or the like.

The process of the present invention utilizes in-mold coatings, many of which are available commercially. Such coatings include GenGlaze® and Stylecoat®, acrylic based appearance in-mold coatings available from Omnova Solutions Inc. of Fairlawn, Ohio, as well as others. These and other coatings are well known to the art. In-mold coating injection devices are available commercially from EMC² of Sterling Hills, Michigan, and Morrell of Auburn Hills, Michigan. The in-mold coating can be injected onto the substrate as known in the art. A predetermined amount of in-mold coating is utilized to coat the molded substrate as desired. Injection systems for in-mold coating materials are well known in the art and need not be described in detail herein. The following description of such a system is provided herein to facilitate a better understanding of the present invention. The in-mold coating apparatus 422 comprises an in-mold coating injector having a shut off pin which supplies a metered amount of a coating material. A supply pump is generally utilized to supply the in-mold coating material into a metering cylinder from a storage vessel or the like. The in-mold coating is injected from the metering cylinder into the mold cavity through in-mold coating injection inlet with a pressurizing device utilizing hydraulic, mechanical, or other pressure. When the in-mold coating apparatus is activated during an injection mode, the coating material flows through the in-mold coating injection inlet and into the mold cavity between an inner wall of mold half 442 and a surface of the molded substrate. Once a predetermined amount of in-mold coating has been injected into the mold cavity, the in-mold coating apparatus 422 is deactivated thus causing the flow of coating to cease. The in-mold coating subsequently cures in the mold cavity and adheres to the substrate surface to which the same was applied. As known in the art, the curing can be caused by the residual heat of the substrate or mold halves, or by reaction between the components of the in-mold coating. The in-mold coating is injected into the mold cavity at a pressure ranging generally from about 500 to about 5000 psi, desirably from about 1500 to about 4500 psi, and preferably from about 2000 to about 4000 psi. One suitable in-mold coating, an acrylic in-mold coating, is found in U. S.

Patent No. 5,777,053. The main advantage of acrylic coatings is the high degree of resistance to thermal and photoxidation and to hydrolysis, giving coatings that have superior color retention, resistance to embrittlement and exterior durability. Low- molecular weight acrylic resins having an average functionality of two to three and containing few molecules that are nonfunctional or only monofunctional, are useful in the present invention. Epoxy resins are also useful as in-mold coatings in the present invention. A principal use of epoxy resins is as a component in two- package primer coatings. One part contains the epoxy resin and the other part contains a polyfunctional amine. Amine-terminated polyamides, sometimes called amido-amines, are widely used. A preferred acrylic resin is an epoxy-based oligomer having at least two acrylate groups and at least one copolymerizable ethylenically unsaturated monomer, and at least one copolymerizable monoethylenically unsaturated compounds having a -CO-, group and a -NH₂-, NH, and or -OH- group. The present invention also contemplates the use of other resin coatings, such as alkyds, polyesters, urethane systems, amino resins, phenolic resins, and silicone resins. See e.g., Kirk Othmer, Encyclopedia of Chemical Technology, Vol. 6 (4^th ed. 1993) at pp. 676-690.

In-mold coatings comprising five components, namely 1 ) a saturated aliphatic polyester intermediate urethane

2) an aliphatic polyether

3) an aliphatic or cycloaliphatic portion (meth)acrylate

4) hydroxy alkyl (meth)acrylates 5 5) vinyl substituted aromatics have been found to have particular utility in the practice of this invention. In- mold coating compositions are prepared as follows. The polyester urethane acrylate is mixed with the vinyl substituted aromatic monomers such as styrene, the saturated aliphatic or cycloaliphatic (meth) acrylates such as isobornyl acrylate, and

L0 the hydroxyalkyl methacrylate, such as hydroxypropyl methacrylate. After these compounds are mixed, fillers and additives, such as cure inhibitors, light stabilizers, lubricants, etc., are added and mixed. The free radical generating initiator is added last. The polyacrylate ester of a polyol can be present in the polyester urethane acrylate from the supplier. This in-mold coating composition is clear after curing.

L5 Any of the coatings contemplated for use in the present invention can be colored by utilizing a pigment, a colorant, etc., in a desired or effective amount to yield a desired color, tint, hue, or opacity. Pigments, pigment dispersions, colorants, etc. are well known to the art and include, for example, graphite, titanium dioxide, carbon black, phthalocyanine blue, phthalocyanine red, chromium and

20 ferric oxides, aluminum or other metal flake, and the like.

When an in-mold coating having a specific color is desired, one or more pigments, colorants, etc., can be utilized in suitable amounts. As known to the art, often times various pigments or colorants are added with a carrier, for example, a polyester, so that they can be easily blended. Any suitable mixing vessel can be

25 utilized, and the various components and additives mixed until the compounds are blended. Even if pigments are not contained in the blend, the mixture at this point is not clear.

All of the above-described in-mold coating compositions that may be utilized in the present invention may contain other additives and fillers, etc., in amounts 0 known to the art. For example, various cure inhibitors such as benzoquinone, hydroquinone, methoxyhydroquinone, p-t-butylcatechol, and the like, can also be utilized. Other additives may include an accelerator, such as cobalt octoate. Other classes of accelerators include zinc, or other metal carboxylates. Various light stabilizers can also be utilized such as, for example, the various hindered amines (HALS), substituted benzophenones, and substituted benztriazoles, and the like. Lubricants and mold release agents are generally utilized with specific examples including various metal stearates, such as zinc stearate or calcium stearate or phosphonic acid esters. Reinforcing fillers, such as talc, can be utilized. Other 5 additives include hardeners, thixotropes, such as silica, and adhesion agents, such as polyvinyl acetate.

EXAMPLES

Example 1

L0 A mold used to produce the plaque 200 shown in FIG. 9 was made. The mold cavity width is 12.0 inches. The mold cavity length is 20.5 inches. The mold has a hydraulic mold gate located in the center of the cavity for injection of a substrate. The mold has a tapered tab for the introduction of the IMC onto the part surface. The tab is located at the edge portion of the mold. The tab and Section A

[5 have thicknesses of 0.120 mils. Section B is 0.100 mils thick. Section C is 0.080 mils thick. Section D is 0.060 mils thick. As shown in FIG. 9, the plaque has four panels in a horizontal plane on the left side of the part and four panels in a vertical plane on the right side of the part. The panels on the horizontal plane on the right side of the part measure 6.0 inches long and 5.125 wide. The panels on the vertical

20 plane measure 1.50 inches wide and 20.5 inches long. The plaque does not have an in-mold coating containment flange. The mold was placed in an 850 ton Cincinnati Milacron Vista injection molding machine. ABS resin heated to a temperature of 480°F was injected into the mold cavity thus producing the part shown in FIG. 9 having sections with the above-described dimensions. FIG. 9 is a 5 front view of the plaque. As stated above, the various sections A-D represent varying thicknesses of the plaque in the defined areas. The front of the plaque shown in FIG. 9 is a smooth surface and thus, the backside of the plaque shows the various thickness contour variations. After a hold time of approximately 120 seconds, an in-mold coating, Stylecoat® was injected through the tab portion of the 0 plaque onto the front surface of the plaque. The chart below details how the in- mold coating flowed onto the different sections of the plaque. <img file="WO03092979A1_D0001.tif" />

* 1 mil = 0.001 inch

It was determined from the part surface area to be coated, and the desired coating thickness, that an in-mold coating amount of 1.2 cubic inches would produce a full in-mold coating shot and cover the entire plaque. As can be seen from the chart, upon in-mold coating injection onto the plaque surface, the top left panel and the inside vertical panel (runner section A) were preferentially coated when 25% of a full shot was utilized. Thus, this example shows that Section A is an effective runner section whereby the coating prefers to flow down the plaque along Section A and out to the side thereof before flowing into thinner sections B, C, and D. When 50% of a full in-mold coating shot was utilized, the in-mold coating began to flow from Section A and B into Section C. It is important to note that the plaque shown in FIG. 9 does not contain an in-mold coating containment flange. When coating levels above 50% of a full shot were utilized, the same leaked or seeped out of the mold cavity through the parting line. Thus, the need is clearly shown for an in-mold coating containment flange in order to keep the in-mold coating on the desired substrate surface. It has further been shown by the example that preferential coating of preferred or runner sections of a plaque can be obtained by utilizing the thickness of the wallstock to guide the in-mold coating across the part surface.

Example 2

FIG. 10 shows a thermoplastic article with a variety of substrate (thermoplastic) thicknesses. It was shown through experimentation that in-mold coating flow is influenced by the substrate thickness. The example parts were generated using a 50-ton injection molding machine, a 6-inch square steel mold cavity fitted with an IMC injection nozzle. The substrate material was a PET thermoplastic and the in-mold coating was OMNOVA's Stylecoat^® IMC. The mold temperature was 250°F with a 30 second delay time prior to IMC injection. ln FIG. 10, sections E, F, and G are representations of varying part thickness as shown by the chart below. Section H represents the in-mold coating tab design utilizing a thicker middle section which facilitates an in-mold coating flow channel at the in-mold coating nozzle tip site. Section I represents the thin sectioned containment flange.

The overall objective in designing a mold with thin and thick sections is to preferential channel the in-mold coating flow path in a desirable fashion. This can be manifested in several ways which include:

1. A channeling of the in-mold coating flow at the in-mold coating tab site (Section H) which preferentially deposits the in-mold coating inside the mold parting line onto the surface of the part.

2. A channeling of the in-mold coating flow in the part to more critical areas to fill since selective in-mold coating may be necessary in certain article designs (Sections E, F, and G).

3. A restriction of in-mold coating flow along the periphery of the mold to contain the in-mold coating on the surface of the part and within the parting line (Section I).

The observed in-mold coating coverage for the 6x6 mold is as follows:

<img file="WO03092979A1_D0002.tif" />

Note: Section E = 115 mils (thickness)

Section F = 85 mils

Section G = 60 mils

Section H = in-mold coating tab - 60 mils

Section I = containment flange - 25 mils * 1 mil = 0.001 inch

In the example(s) we have shown that this preferential flow mechanism has advantages which include:

1. Preferential IMC flow and deposition to selected regions on a part as a result of varying thickness.

2. Achieving the containment of IMC on the part surface within the parting line resulting from a designed thin sectioned, IMC flow restricting, "containment flange." Example 3 - Removable in-mold coating containment flange

The following example illustrates in-mold coating containment on a desired surface of a molded substrate when a removable in-mold coating containment flange is utilized. Two molds were created, with the molds being identical except for one of the molds was fabricated to have a removable in-mold coating containment flange. The molds were formed as a plaque similar to that shown in FIG. 11 and cross section in FIG. 12. The flangeless plaque had a length of 19.5 inches (495.3 mm), a width of 4.75 inches (120.65 mm) and a depth of 0.100 inches (2.54 mm). The second identical plaque mold further included a removable containment flange having a width of 0.125 inches (3.175 mm) around the entire perimeter of the plaque except for the tab portion of the main surface where the in- mold coating was injected, and was connected to the plaque main surface between a show surface and a back surface as shown in FIG. 12. The tab area of the main surface of both molds had a length of 2 inches (50.8 mm) extending from a 2.25 inches (57.15 mm) width attached to the plaque main portion tapered to 1.25 inches (31.75 mm) at the other end of the tab. The connection point between the plaque and the removable containment flange had a thickness or depth of 0.005 inches (0.127 mm). The removable flange was tapered from the attachment point as shown in FIG. 12 out to a thickness of 0.015 inches (0.381 mm) to form a triangle having a right angle. The angle of the containment flange at the attachment point was 15 degrees and thus the angle between the containment flange and the vertical surface (as shown in FIG. 12) of the plaque main portion was 75 degrees. The plaques of this example were molded on a Toshiba 950 injection molder with barrel temperature zones set from 530°F to 560°F utilizing Ticona PA 6/6 Nylon and XZ-31 Black Stylecoat® available from OMNOVA Solutions Inc. The mold halves were heated to 278°F. 18.85 grams of in-mold coating were injected into the mold at the tab portion of the substrate show surface.

<img file="WO03092979A1_D0003.tif" /><img file="WO03092979A1_D0004.tif" />

<img file="WO03092979A1_D0005.tif" />

**Denotes leakage at parting line and out the vent channels on the mold.

As can be seen from the above chart, the mold without the removable containment flange allowed the in-mold coating to leak off the surface of the molded plaque no matter what clamp tonnage was applied to keep the mold halves together. The mold with the removable containment flange exhibited little or no in- mold coating leakage off the plaque show surface. Only when low amounts, i.e. four tons per square inch or less of pressure were utilized to keep the mold halves together, did a small amount of coating leak off the intended surface. It is important to note that it is believed that the in-mold coating leakage occurred at the tab because the tab portion was not surrounded with the removable containment flange in that area.

In accordance with the patent statutes, the best mode and preferred embodiment have been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims.