Abstract: A pressure-activated valve for conducting pressurized gas into a mold cavity of an injection molding apparatus is preferably constructed as an easily replaceable unit. The preferred valve includes a pin having a flared head section. The head section has a planar face transverse to an axis of the pin so as to approximately conform to a neighboring contour of the mold cavity. The valve also includes a body in which a passageway intersects a second end of the body to define a port and a flaring seat communicates through a first end of the body between the passageway and the mold cavity. A restrainer which abuts against the second end of the body includes a guideway aligned with the passageway through the body as well as at least one cross-channel which admits pressurized gas to that passageway through the port. The pin extends through both the passageway and the guideway so that its head portion is positioned near the seat.

Abstract: A method for molding a plastic part comprises preforming a film laminate and insert molding a plastic substrate against the film laminate. According to one embodiment, the film laminate is preformed with re-entrant edge portions. The insert molding step involves positioning the film laminate in a mold cavity, closing the mold and injecting molten resin into the mold cavity against the film laminate. The force of the closing of the mold and the injection of the resin causes the re-entrant edge portions to curl up under the solidifying resin to ensure complete coverage of the longitudinal edges of the plastic substrate by the film laminate. According to another embodiment, a stencil of an image is made in the film laminate prior to the insert molding. The resin injected into the mold flows into the stencil so that the image is visible against the surrounding surface of the film laminate.

Abstract: A method for molding a plastic part comprises preforming a film laminate and insert molding a plastic substrate against the film laminate. According to one embodiment, the film laminate is preformed with re-entrant edge portions. The insert molding step involves positioning the film laminate in a mold cavity, closing the mold and injecting molten resin into the mold cavity against the film laminate. The force of the closing of the mold and the injection of the resin causes the re-entrant edge portions to curl up under the solidifying resin to ensure complete coverage of the longitudinal edges of the plastic substrate by the film laminate. According to another embodiment, a stencil of an image is made in the film laminate prior to the insert molding. The resin injected into the mold flows into the stencil so that the image is visible against the surrounding surface of the film laminate.