Method for modifying existing mold systems to utilize an in-mold apparatus

1. A method of modifying an injection molding system to be operable with a dispensing apparatus so as to render said molding system capable of providing coated articles, said method comprising:

a) providing

1) a molding system comprising:

(A) first operating system, and

(B) a molding machine that comprises a mold comprising

(i) first and second mold sections, and

(ii) in at least one of said mold sections, at least one nozzle for injecting a substrate-forming material, said first operating system communicating with said mold sections such that said sections can be actuated between opened and closed conditions, said first and second mold sections forming a mold cavity when in said closed condition, and

2) a dispensing apparatus that can hold and deliver a coating composition, said dispensing apparatus comprising at least one of a second operating system for controlling delivery of said coating composition and a data storage means;

b) modifying said molding machine to communicate with said dispensing apparatus;

c) adapting said dispensing apparatus to function with said molding system so as to deliver, based on a set of predetermined parameters, said coating composition into said mold when said mold sections are in said closed condition, and

d) modifying said mold to include at least one of a flow control which utilizes substrate compressibility to control at least a predetermined portion of one surface of a molded article formed and contained in said mold while said mold sections are in said closed condition so as to provide said coated article.

2. The method of claim 1 wherein said molding system and said coating dispensing apparatus are provided by two separate sources.

3. The method of claim 1 wherein said set of predetermined parameters includes dispensing a set amount of said coating composition at a set point in the molding cycle when said substrate is compressible.

4. The method of claims 1 further comprising modifying said mold to further comprise at a desired location at least one nozzle for injecting and directing said coating composition into the mold cavity formed by said mold section to produce a laminar flow of said coating composition across a show surface on said substrate, said dispensing apparatus optionally being selectively and fluidly connectable with the at least one nozzle for the coating composition.

5. The method of any of claims 1 wherein said dispensing apparatus is selectively connectable with said molding machine, said dispensing apparatus optionally comprising a moveable cart system to allow said dispensing apparatus to be re-positionable or being a portable system mountable on said machine.

6. The method of claims 1 wherein said modifying said mold to include at least one flow control includes modifying said mold cavity to produce at least one zone of low substrate compressibility adjacent said show surface.

7. The method of claims 1 further comprising modeling the flow of said coating composition across said substrate so as to determine optimal settings for at least one of said molding machine and said dispensing apparatus an optionally modifying said mold based on said flow modeling.

8. The method of claims 1 further comprising at least one of the following:

a) determining at least one of a preferred substrate material and a preferred material for said coating composition;

b) determining at least one of an optimal mold temperature and an optimal substrate temperature for injecting said coating composition into said mold, and

c) mounting at least one sensor on said mold for measuring at least one mold variable and connecting said at least one sensor to one of said dispensing apparatus and said operating system.

9. The method of claim 1 wherein said operating system of said molding system controls the delivery of said coating composition into said mold.

10. The method of claim 1 wherein said coating composition comprises component parts, said method further comprising providing a mixing apparatus to blend and mix said component parts before injection of said coating composition.

11. The method of claim 1 wherein said coating dispensing apparatus is a self-contained unit.

12. The method of claim 1 wherein said second operating system further includes a remote transmitter, positioned on a mold section, having the ability to generate a signal upon closure of said mold sections.