Mold coating of freshly molded articles

Claim 1

A method of molding a composite polymeric article comprising a substrate and a special purpose skin of predetermined thickness on a surface of said substrate, said method comprising the steps of: molding said substrate between separable dies which coact in a first fully-closed position to define a mold cavity corresponding in size and shape to said substrate, and nest one within the other to provide a polymer containment seal around said cavity; allowing said substrate to harden in said cavity; separating one of said dies from said surface of said substrate to provide a first gap therebetween which is greater than said predetermined thickness of said skin but insufficient to unnest said dies; injecting a metered amount of skin-forming material into said gap in such a manner as to substantially hydraulically immobilize said substrate in said cavity during said separating, said amount being sufficient to provide said predetermined thickness but insufficient to fill said gap; applying molding pressure to said one die to reduce said one gap to a second gap which is commensurate with said predetermined thickness, and to distribute said injected material substantially uniformly throughout said second gap and over said surface; maintaining said pressure while said material bonds to said surface and solidifies sufficiently to permit complete separation of said dies without disruption of the skin thusly formed; and completely separating said dies and removing said composite from said cavity.

Claim 2

A method of molding a composite polymeric article comprising a substrate and a special purpose skin of predetermined thickness on a surface of said substrate, said method comprising the steps of: molding said substrate between separable dies which coact in a first fully-closed position to define a mold cavity corresponding in size and shape to said substrate, and nest one within the other to provide a polymer containment seal around said cavity; allowing said substrate to harden in said cavity; separating one of said dies from said surface of said substrate to provide a first gap therebetween which is greater than said predetermined thickness of said skin but insufficient to unnest said dies; injecting a metered amount of skin-forming material into said gap in such a manner as to substantially hydraulically immobilize said substrate in said cavity during said separating, said amount being sufficient to provide said predetermined thickness but insufficient to fill said gap; applying molding pressure to said one die to reduce said one gap to a second gap which is commensurate with said predetermined thickness, and to distribute said injected material substantially uniformly throughout said second gap and over said surface; maintaining said pressure while said material bonds to said surface and solidifies sufficiently to permit complete separation of said dies without disruption of the skin thusly formed; and completely separating said dies and removing said composite from said cavity.

Claim 3

A method of molding a composite polymeric article comprising a substrate and a special purpose skin of predetermined thickness on a surface of said substrate, said method comprising the steps of: molding said substrate between separable dies which coact in a first fully-closed position to define a mold cavity corresponding in size and shape to said substrate, and nest one within the other to provide a polymer containment seal around said cavity; allowing said substrate to harden in said cavity; injecting a metered amount of skin-forming material between said surface of said substrate and the die which formed that surface in such a manner as to separate said surface-forming die from said surface by a first gap which is greater than said predetermined thickness of said skin but insufficient to unnest said dies and to substantially hydraulically immobilize said substrate in said cavity during said separating, said amount being sufficient to provide said predetermined thickness but insufficient to fill said first gap; applying molding pressure to said surface-forming die to reduce said one gap to a second gap which is commensurate with said predetermined thickness and to distribute said injected material substantially uniformly throughout said second gap and over said surface; maintaining said pressure while said material bonds to said surface and solidifies sufficiently to permit complete separation of said dies without disruption of the skin thusly formed; and completely separating said dies and removing said composite from said cavity.

Claim 4

A method of molding a composite polymeric article comprising a substrate and a special purpose skin of predetermined thickness on a surface of said substrate, said method comprising the steps of: molding said substrate between separable dies which coact in a first fully-closed position to define a mold cavity corresponding in size and shape to said substrate, and nest one within the other to provide a polymer containment seal around said cavity; allowing said substrate to harden in said cavity; injecting a metered amount of skin-forming material between said surface of said substrate and the die which formed that surface in such a manner as to separate said surface-forming die from said surface by a first gap which is greater than said predetermined thickness of said skin but insufficient to unnest said dies and to substantially hydraulically immobilize said substrate in said cavity during said separating, said amount being sufficient to provide said predetermined thickness but insufficient to fill said first gap; applying molding pressure to said surface-forming die to reduce said one gap to a second gap which is commensurate with said predetermined thickness and to distribute said injected material substantially uniformly throughout said second gap and over said surface; maintaining said pressure while said material bonds to said surface and solidifies sufficiently to permit complete separation of said dies without disruption of the skin thusly formed; and completely separating said dies and removing said composite from said cavity.