In-mold coating barrier for a substrate injection orifice

1. An in-mold coated substrate, comprising:

the substrate; and

the in-mold coating, said substrate including a barrier, said barrier including a raised rim element extending around the perimeter of a substrate injection inlet area on the substrate to prevent said in-mold coating from ingressing to said substrate injection inlet area, and said in-mold coating at least coating a substrate area outside of said raised rim element.

2. A substrate according to claim 1 , wherein said substrate injection inlet area is substantially free of said in-mold coating.

3. A substrate according to claim 2 , wherein said rim element has a maximum height when compared to a height of said substrate injection inlet area of from about 1.05:1 to about 10:1, and a width of about 0.10:1 to about 5:1.

4. A substrate according to claim 3 , wherein said rim element height when compared the height of said substrate injection inlet area is from about 1.75:1 to about 3:1, and said width is about 0.25:1 to about 1:1.

5. A substrate according to claim 4 , wherein said rim element height when compared the height of said substrate injection inlet area is about 2:1, and said width is 0.35:1 to about 0.50:1.

6. A substrate according to claim 3 , wherein said rim element includes at least one wall extending away from said substrate at an angle substantially perpendicular to the surface of said substrate adjacent said barrier.

7. A substrate according to claim 6 , wherein said rim element includes two said walls and has a substantially constant thickness therebetween.

8. A substrate according to claim 6 , wherein said rim element also includes a tapered or rounded portion.

9. A substrate according to claim 7 , wherein said walls are of an equal height.

10. A substrate according to claim 3 , wherein said barrier rim element is substantially cylindrical in shape, and wherein said substrate is thermoplastic.

11. A method for in-mold coating a substrate, comprising the steps of:

(a) injecting a thermoplastic substrate forming material into a mold cavity from an injection inlet point at a temperature above a melting point of said substrate forming material;

(b) forming a substrate in said mold cavity, said substrate comprising a barrier on a surface thereof, said barrier including a raised rim element extending around the perimeter of said injection inlet point and a substrate injection inlet area surrounded by said rim element;

(c) injecting an in-mold coating into said mold cavity on said surface of the substrate which includes said barrier; and

(d) allowing said in-mold coating to flow across the surface of said substrate, wherein the barrier prevents said coating from flowing onto said substrate injection inlet area.

12. A method according to claim 11 , wherein said substrate injection inlet area is substantially free of said in-mold coating.

13. A method according to claim 12 , wherein said rim element has a maximum height when compared to a height of said substrate injection inlet area of from about 1.05:1 to about 10:1, and a width of about 0.10:1 to about 5:1, and wherein said substrate injection inlet point includes a gate pin.

14. A method according to claim 13 , wherein said rim element height when compared the height of said substrate injection inlet area is from about 1.75:1 to about 3:1, and said width is about 0.25:1 to about 1:1.

15. A method according to claim 14 , wherein said rim element height when compared the height of said substrate injection inlet area is about 2:1, and said width is 0.35:1 to about 0.50:1.

16. A method according to claim 15 , wherein said rim element includes at least one wall extending away from said substrate at an angle substantially perpendicular to the surface of said substrate adjacent said barrier.

17. A method according to claim 16 , wherein said rim element includes two said walls and has a substantially constant thickness therebetween.

18. A method according to claim 17 , wherein said rim element also includes a tapered or rounded portion.

19. A method according to claim 18 , wherein said walls are of an equal height.

20. A method according to claim 19 , wherein said barrier rim element is substantially cylindrical in shape.

21. The method of claim 11 wherein the mold cavity has a volume that remains substantially constant throughout steps a) to d).

22. The method of claim 11 wherein the mold cavity is defined by at least two mold members that remain a substantially fixed distance relative to one another during steps a) to d).

23. The method of claim 11 , wherein the mold cavity is defined by at least two mold members that are not opened or unclamped in or between steps a) to d).

24. A mold half comprising:

a substrate injection inlet; and

a barrier forming relief formed in said mold half, said relief extending around said substrate injection inlet to prevent an in-mold coating from entering the substrate injection inlet, said relief having a width and a height.

25. A mold half according to claim 24 , wherein said relief includes at least one wall extending into said mold half at an angle substantially perpendicular to a surface of the mold half adjacent said barrier forming relief.

26. A mold half according to claim 25 , wherein said barrier forming relief includes two said walls and has a substantially constant width therebetween.

27. A mold half according to claim 26 , wherein said walls are of substantially equal height.

28. A mold half according to claim 25 , wherein said relief also includes a tapered or rounded portion.

29. A mold half according to claim 24 , wherein said relief is substantially cylindrical in shape around said substrate injection inlet.