Abstract: According to various aspects, exemplary embodiments are provided of EMI shielding materials. In one exemplary embodiment, an EMI shielding material generally includes a conductive metal layer disposed on a thin carrier film. The EMI shielding material may be sufficiently compliant such that the conductive metal layer and thin carrier film are capable of conforming to an irregular surface when the EMI shielding material is applied to the irregular surface.

Abstract: A molding apparatus includes a mold (12,14) defining a plurality of mold cavities (34,36). Fluidly connected to the mold cavities (34,36) are one or more first composition injectors (30) and one or more second composition injectors (32) for delivery of, respectively, the molten material from which the molded article is to be formed and a composition to coat the article so formed.

Abstract: A method of modifying an existing injection molding system so that the system can produce articles wherein at least one of the surfaces is coated while the article remains in the mold. The method includes the steps of providing a dispensing system for a coating composition and modifying an injection molding system to communicate with the dispensing system. The modification can include at least one nozzle to inject and direct the coating composition onto at least one surface of the molded article.

Abstract: A method of designing and producing a mold for manufacturing an article having at least one surface coated by a coating. The method including evaluating the article design to determine the probable flow characteristics of the mold, an optimal flow of the coating composition, and an optimal location for the coating composition injector. A mold is designed and produced based on the evaluation.

Abstract: A molding apparatus includes a mold (12,14) defining a plurality of mold cavities (34,36). Fluidly connected to the mold cavities (34,36) are one or more first composition injectors (30) and one or more second composition injectors (32) for delivery of, respectively, the molten material from which the molded article is to be formed and a composition to coat the article so formed.

Abstract: A quality assurance method for in-mold coating of molded articles in which coated articles produced with one set of molding and coating process variables are inspected and changes are made to one or more of the variables based on the observations. Changes to one or more such variables based on the observations aid in producing subsequent coated articles of consistently high quality.

Abstract: An in-mold coating method wherein the time at which a coating substrate is injected onto a surface of a molded substrate is determined by the internal mold temperature and/or pressure. By regulating the point at which the in-mold coating is injected based on the internal mold temperature and/or pressure, an operator can assure that the in-mold coating is injected when the surface of the molded substrate is in an ideal condition for in-mold coating adhesion.

Abstract: A method of modifying an existing injection molding system so that the system can produce articles wherein at least one of the surfaces is coated while the article remains in the mold. The method includes the steps of providing a dispensing system for a coating composition and modifying an injection molding system to communicate with the dispensing system. The modification can include at least one nozzle to inject and direct the coating composition onto at least one surface of the molded article.

Abstract: A method of designing and producing a mold for manufacturing an article having at least one surface coated by a coating. The method including evaluating the article design to determine the probable flow characteristics of the mold, an optimal flow of the coating composition, and an optimal location for the coating composition injector. A mold is designed and produced based on the evaluation.

Abstract: A method of injection molding and in-mold coating an article is provided. A molten resin is injected into a molding cavity (16) until the molding cavity (16) is substantially filled. The injected molten resins is allowed to cool in the molding cavity (16) to form a molded article. A coating composition is injected into the molding cavity (16) and onto the molded article to in-mold coat the molded article when at least a surface to be coated of the molded article has reaches a modulus sufficient to support the coating composition.

Abstract: A method is provided for metering and controlling the dispense rate of an in-mold coating composition into a mold cavity (16) and onto a thermoplastic molded article contained therein. A heated thermoplastic material is injected into the mold cavity (16). The thermoplastic material is allowed to form a thermoplastic article in the mold cavity (16). An in-mold coating composition is injected into the mold cavity (16) and onto the thermoplastic article. The amount of said in-mold coating composition injected into the mold cavity (16) and onto the article is controlled. The rate that the in-mold coating composition is injected into the mold cavity (16) and onto the in-mold coating article is controlled.