MXPA01003087A - Composite product and method and apparatus for its formation - Google Patents

Abstract

A plastic composite (10) includes colored plastic composite molded in an injection mold and including a multi-layer molding system and a process and apparatus for manufacturing the multi-layer molding system.

Description

COMPOSITE PRODUCT AND METHOD AND APPARATUS FOR FORMATION DESCRIPTION OF THE INVENTION This invention relates to plastic compounds and more particularly to plastic compounds having one or more congruent multiple colors or layers formed by injection molding. Several proposals have been suggested and put into practice for the manufacture of plastic compounds for use in interior finishing and exterior finishing products of automobiles. One methodology is to form plastic or metal substrates and apply multiple coatings on them to produce a part with class A surfaces at high gloss. The substrates can be formed from steel or from any known plastic material from a wide range such as blends of ABS, L ABS, ABS / PC, PU, TPO, PET, PBT or other equivalent high strength plastic materials suitable for the Injection molding of a product form. Coatings for such substrates may be selected from known coatings such as a primer coating, an adhesion promoter, a base coat, a pure coat and, in the case of metals, an electrodeposition coating. Examples of such coatings were published in U.S. Patent Nos. 4,681,811 and 5,320,869. The solvents used in such systems can cause undesirable emission problems. Another methodology is to form a paint film and polymer injection material behind the paint film to produce a part with a desired specific color on its exposed Class A surface. Examples of known paint films and injection molded plastic parts are shown in U.S. Patent Nos. 5,432,666 and 5,009,821. Such systems require the manufacture and handling of the film separately. In addition, the film is sometimes difficult to conform depending on the contour of the part that is produced. Yet another methodology for providing a plastic part of color is to provide a coating of varnish that will reduce emissions while producing a crater-resistant surface on the part that is being coated. A system like this is published in US Patent No. 4,396,680. Such systems require the use of conventional coating systems and baking ovens to form a finish on the substrate that has the desired appearance. Yet another methodology is to provide lamination equipment in which a color layer is formed by extrusion and then connected to a substrate. U.S. Patent No. 4,349,592 describes the use of such a technique in the manufacture of a decorative molded exterior finishing part. Still another methodology is to form retro light red amber lamp housings by progressive molding of a long clear housing and by depositing small red and amber non-congruent layers therein. While several methods are suitable for their intended purposes, they all involve processing considerations that produce emissions or require unnecessary handling of one or more layers of material in the manufacture of an interior and exterior finishing product of composite having a surface of a class type. A desired color appearance matched to the components of the adjacent vehicle. Therefore, there is a continuing need in this field or art for an article and its manufacturing method that will make obvious the above problems. Accordingly, it is an object of the present invention to provide an injection molding system of a multilayer colored plastic compound. Another object is to provide such a colored plastic composite having the first and second layers of the injection molded material in a common cavity and arranged in relation one over the other to form a base layer and an upper layer covering the base layer without removal of a tool and where the upper layer constitutes a finished surface coating of the composite in which the base layer comprises the injection molded polymeric material having mixed colors therein and the upper layer comprises injection molded polymeric material with or without embedded light reflecting particles in it to change the color effect of the colors when the compound is viewed from different angles. Still another object of the invention is to provide such a colored plastic composite having the first and second layers of injection molded material in relation to one another to form a base layer and an upper layer covering the base layer without the removal of a tool and wherein the top layer constitutes a finished surface coating of the composite in which the base layer comprises injection molded polymeric material having mixed colors therein of the group consisting of pigments and / or inks and / or particles reflecting the light and wherein the top layer is a clear polymeric material injection molded. Still another object of the invention is to provide a colored plastic composite having a first and second layers of injection molded material in directly molded relation to form a base layer and an upper layer without the removal of the tool covering the layer base and wherein the upper layer constitutes a finished surface coating of the composite and the base layer comprises injection molded polymeric material having mixed particles therein comprising either pigments or inks and containing or not particles embedded therein which reflect Light The upper layer of injection molded material is a polymeric material to protect the base layer. Another object of the invention is to provide a colored plastic composite having a base layer, an intermediate layer and an upper layer covering the base layer and the intermediate layer and wherein the top layer constitutes a finished surface coating of the compound wherein the base layer comprises injection molded polymeric material having mixed colors therein; the intermediate layer comprises injection molded polymeric material having light reflecting particles embedded therein to change the color effect when the composite is viewed from different angles and the injection molded polymeric material of the upper layer. A further object is to provide the colored plastic compound of the preceding object wherein the protective top layer is a clear polymeric material; or a polymer injection molded material having a exterior bright surface with a D.O.I. (image clarity) that reads in the range of 75-100. According to the invention, another object is to provide a process for the manufacture of a multiple layer composite product of injection molded plastic comprising providing a movable mold part and a plurality of stationary mold parts of congruent configuration; sequentially moving the movable mold part with respect to the stationary mold parts to form one or more mold cavities of progressively greater capacity between the mold parts and injecting at least one layer of polymeric material into one of the mold cavities for produce an improved color appearance on the surface in view of the composite product. Another object is to provide such a process wherein a coating layer is injected into one or more of the mold cavities provided with polymeric material having mixed colors thereon to provide a color appearance in the composite injection molded product. Still another object is to provide such a process which further comprises providing polymeric material with or without embedded particles that reflect the light therein and injecting it into one of the cavities of the mold.

Still another object is to provide such a process which further comprises injecting, in one of the cavities of the mold, polymeric material having either colored pigments or inks and light reflecting particles mixed therein. Still another object is to provide such a process which also comprises the injection of polymeric material with color pigments or inks into one of the cavities and the injection of polymer material with particles that reflect the light therein to change the color effect of said pigments. of colors or inks when the compound is seen from different angles. Still another object of the invention is to provide such a process which further comprises the injection of polymeric material into the mold cavities to coat the progressively injected polymeric material to increase the volume of the mold cavities of congruent configuration. Another object is to provide such a process which further comprises the injection of a coating of polymeric material into one of the cavities of the mold and the injection of polymer material having colors or inks into one of the cavities of the mold to form a congruent layer of material against the coating. Another object of the invention is to provide such process that includes providing more than one rotating mold half and providing more than one section of the stationary mold of congruent configuration and provide mold cavities with a progressively greater capacity by varying the dimensions of the stationary mold sections. Yet another object is to provide the process of the preceding object in which the rotating mold halves and the stationary mold sections are respectively provided as coated mold and mold cores. Still another object is to provide the process of the preceding object wherein the material is injected into a first mold cavity on one of the covers and by rotating the cover and moving it towards a second core to form a second mold cavity of a congruent configuration towards a first mold cavity for injecting additional material against the material previously deposited in the cover. Still another object of the present invention is to provide an injection molding apparatus sequentially operated with several stages, having at least one rotary mold half and providing more than one section of the stationary mold of congruent configuration and providing mold cavities with a progressively larger capacity varying the dimensions of the stationary mold sections. Yet another object of the present invention is to provide the apparatus of the preceding object wherein the rotating mold halves and the stationary mold sections are respectively provided as mold covers and as mold cores. BRIEF DESCRIPTION OF THE DRAWINGS The following objects, features and advantages of the present invention will become more apparent from the following description and the accompanying drawings in which: Figure 1 is a perspective view of the apparatus of the present invention; Figure 2 is a perspective view facing the front of a stationary thick plate in Figure 1; Figures 3-5 are perspective views of mold cores shown in Figure 2; Figure 6 is a perspective view of a composite product formed by the present invention; Figure 7 is a cross-sectional view taken along line 2-2 of Figure 6 looking in the direction of the arrows; Figure 8 is a cross-sectional view of another embodiment of the invention; and Figures 9-11 are cross-sectional views of 3 mold cavities with different capacities produced by the apparatus of Figures 1-4. A composite product 10 is shown in Figures 6 and 7 which is representative of the interior finishing and exterior finishing products which must have colors that match the adjacent components within a vehicle structure. In this arrangement the composite product 10 includes an outer layer of injection molded polymeric material 12; an intermediate layer 14 of injection molded polymeric material with or without particles of light reflecting material and a substrate layer 16 of injection molded polymeric material having color pigments or inks. The outer layer 12 has a smooth shiny outer surface 18 defining a class A surface that meets the automotive appearance requirements. The layers 12, 14 and 16 have substantially congruent outer perimeters. Another composite product 20 is shown in Figure 8 having a section 22 of the substrate of injection molded material including color and an outer layer 24 of injection molded material of polymeric material with or without light reflecting material. The outer layer 24 has a smooth outer surface 26 that defines a class A surface that has a smooth glossy appearance that meets the requirements of both smoothness and image clarity (D.O.I) in automotive applications. In a preferred embodiment the reading of the D.O.I is in the range of 75-100. Each of the aforementioned products can be formed in a process that is described by the use of the apparatus 30 shown in diagram in Figures 1-5. The apparatus 30 includes a molding press 32 including an expandable neck section 34. A rotating mold holder or rotating thick plate 36 is continuously carried on a moving thick plate 38. The support of the rotating mold 36 is driven around a horizontal axis by a belt and a drive motor system 40. In the illustrated embodiment, the mold support 36 is shown carrying a plurality of mold covers 42, 44, 46, each forming a mold cavity with a polished surface to meet the finishing requirements of the class A surface. best shown in Figure 2, a stationary thick plate 48 is provided to support a plurality of mold cores 49, 50, 52 that selectively align with each of the mold covers 42, 44, 46 in a process to be described . In Figure 2, the mold cores 49, 50, 52 are separated to show a plurality of underlying sprue holes 54, 56, 58 with nozzles to direct the molten material through the passages in the cores of the mold. mold 49, 50, 52. The molten material is provided to the injection feed systems 60, 62, 64 of a known type including feed hoppers, extrusion cylinders, heaters and headers heated in communication with the drinking holes 54, 56, 58. The mold cores 49, 50, 52, are shown in Figures 3- 5 respectively with profiles or displacement of mass that varies but with configurations of substantially congruent perimeter. In the illustrated embodiment of the invention, the core of the mold 49 (shown in Figure 3) has a three-dimensional profile 49a which, when closed against the cover 42, will produce a mold cavity 63 for receiving an outer layer 12 of the injected material which forms the class A surface 18. In Figure 4, the core of the mold 50 is shown with a three-dimensional profile 50a, smaller than the profile 49a which, when closed against the cover 44 with an outer layer of material injected therein , will define a mold cavity 65 between the mold cover 44 and the core of the mold 49, which is of a progressively greater capacity to accommodate the outer layer of the material retained in the cover 44 and to define a space to receive an intermediate layer. of injected material. In Figure 5, the core of the mold 52 is shown with a three-dimensional profile of less mass (volume) than the core of the mold 50, which when closed against the carrier layers of the cover 12, 14 will define a cavity 67 between the mold cover and the core of the mold 52 of still greater capacity to accommodate the previously injected layers 12, 14 that are retained on the cover while defining a space in the closed mold to receive the layer 16 of a composite product. The press 30 is opened and closed by a drive system not shown which is operated to move the moving thick plate 38 on the tie bars 66, 68, 70 and 72. The press drive system can be of the types known including hydraulic cylinders, electric motor-driven screw transmissions, oscillating connections and the like as are well known to those skilled in the art and which do not form part of the present invention. More specifically, the mold covers 40, 42, 44 when placed inside the mold press 30 are rotated by the rotary mold holder 36 with respect to the moving thick plate 38. The moving thick plate 38 is driven in a manner such that the mold covers 40, 42, 44 and the mold cores 49, 50, 52 close when the molten material is directed into a mold cavity defined between the cover and the respective mold core sections. The mold covers 40, 42, 44 are separated along a dividing line and are used normal ejectors both to retain the molded material on the cover and to remove it during the process to be described. The molding press 30 includes a hot wheel system for supplying the molten mixture in the mold cavities. An injection system 74, 76, 78 (shown in diagram in Figure 2) includes known hot wheel systems and an injector for each of the holes 54, 56, 58 respectively and is shown in diagram as communicating through of passages in each of the mold cores 49, 50, 52 respectively and as communicating respectively with each of the feed systems 60, 62, 64 having a known thread mechanism 80 that receives a predetermined desired plastic composition, a supply hopper 82. This arrangement allows the process to conform to a particular polymer / additive combination that is most suitable for application in the process of the present invention to obtain the best color composite resulting from the present invention. Although three of the mold covers 42, 44, 46 and of the mold cores 49, 50, 52 are shown, the number may be decreased or increased in number and the process of the present invention, which generally includes a process for the manufacture of a multilayer composite product of injection molded plastic, comprising providing at least a movable mold part such as mold cover 42 and a plurality of stationary mold parts such as mold cores 49, 50, 52 and moving sequentially the part of the movable mold with respect to the stationary mold parts to form one or more mold cavities (shown at 63, 65, 67 in Figures 9, 10 and 11), of progressively increased capacity and to inject at least one layer of polymeric material within one of the mold cavities to produce a smooth glossy appearance on the surface in view of the composite product as produced by the surface finish on the mold cover defining the portion of the mold cavity by injection. If more than one moving mold part is provided as shown in Figure 2, at 42, 44, 46, the process may involve a series of operations including impact positions, first, second and third in SPi, SP2, SP3 in Figure 2. As illustrated in SPi the mold cover 42 is first closed against the core of the mold 49 to define the cavity of the mold 63 (the smallest cavity) into which the polymer material of the outer layer is to be injected.; at the same time in SP2 of mold cover 44 carrying the pre-injected outer layer of material it is closed against the core of the mold 50 to define the next size of the cavity of the mold 65 to which the polymeric material of the intermediate layer is directed; at the same time the SP3 the cover of the mold 46 is closed against the core of the mold 52 so that the base layer can be injected into the cavity 67 of the next size mold against two layers of the previously deposited material retained in the mold cover 46. Following the injection of the materials into the closed molds, the movable thick plate 38 separated from the thick plate 48 and a finished part (comprising three layers of injected material) is exerted from the mold cover 46. The carrier is then rotated by rotary tool or thick plate 36 for moving the mold cover 46 to the first impact position SPi of the mold cavity, the mold cover 42 moves to the second impact position of the mold cavity SP2 and the cover moves from the mold 44 to a third impact position of the mold cavity SP3; the thick plates are moved to close the mold covers against the mold cores and the first, second and third impacts of the injection molded material are injected as described above. The process that is repeated continuously. While the process is shown with the part of the mold cavity is carried to the rotating tool carrier or thick plate 36, the process also contemplates bringing the mold cores into the rotating tool carrier and bringing the mold covers (cavities) to the stationary thick plate 48. In such a change of locations, the door will be located in such a way that the first surface formed will be the base; it will be carried in the core to a second station in which the intermediate layer will be formed and then to a third station where the first finished surface will be formed in the part of the mold cavity in the third station. The process may include an injection shot to form the cover layer that is injected into one or more of the mold cavities providing polymeric material having mixed colors thereon to provide an improved color appearance in the injection molded composite product. . Such a process, if desired, may further comprise providing polymeric material with or without embedded particles that reflect light therein and injecting it into one of the mold cavities. The process may further comprise injecting into one of the mold cavities polymeric material having either pigments or color inks or both and light reflecting particles mixed therein.

The process may further comprise injecting polymeric material with pigments or color inks into one of the cavities and injecting polymeric material with particles that reflect light therein to change the color effect of such pigments or color inks when the composite be seen from different angles. The process may also comprise injecting polymer material into the mold cavities to coat the injected polymer material in progressively increased volume in the mold cavities having substantially congruent outer perimeter profiles. The process may additionally comprise injecting a coating of polymeric material into the cavities of the mold to coat the first layer of polymeric material in one of the cavities of the mold and inject polymeric material having colors or inks into one of the cavities of the mold to form the first layer of material; The process can also provide three or more rotating mold halves and provide three or more fixed mold sections and provide a progressively greater mold cavity capacity by varying the dimensions of the fixed mold sections while retaining the congruent outer perimeter profiles . For a better understanding of the injection molding apparatus operated sequentially of several phases of the present invention, having more than one rotary mold half and providing more than one fixed mold section and providing a progressively increased capacity in the cavities by varying the dimensions of the fixed mold sections, a diagram thereof is shown in Figures 9-11, wherein the movement of one of the movable mold covers or cavities is illustrated. In the sequence of the sections shown in Figures 9 to 11, the cover of the mold 42 is followed, when placed in the positions SPi, SP2 and SP3, inside the molding press 32, by the process of sequentially advancing the cover of the mold 42 with respect to the three stationary mold cores 49, 50, 52 located within the molding press 32 as discussed previously, to form one or more of the mold cavities of similar outer perimeter profile and for a capacity progressively larger and injecting at least one layer of polymeric material into one of the cavities of the mold, to produce a color appearance on the surface in view of the composite product. Therefore, as shown in Figure 9, the cover of the mold 42 is placed on the core 49 when the molding press 32 is closed to form the mold cavity 63. As shown in Figure 10, the cover of the mold mold 42 is placed in the core 50 when the press stops molding 32 is closed to form the mold cavity 67 between a layer of material previously deposited in Figure 9. The core 50 has a section 50a of smaller mass than the section core 49a so that a mold cavity of a capacity progressively The larger is defined by that reason, so that the layer of material deposited in the mold cavity can be accommodated and provide a mold cavity 67 for the injection of a second layer of material. As shown in Figure 11, the mold cover 42 (with two layers of material deposited on the tool) is placed in the core of the mold 52 when the molding press 32 is closed. The core 52 has a section 52a of smaller mass than the core section 50a to form a mold cavity 62 of a progressively larger capacity (with a similar outer perimeter profile) that will allow the previously deposited layers of the injected material to settle. the tool and to form the mold cavity 67 by depositing a third layer of injection molded material in the same tool, i.e. the mold cover or cavity 42. According to the illustrated equipment, the rotating thick plate 36 first place the mold cover 42 on the molding press 32 and close against the core of the mold 49. At this point in the process a shot of the molten polymeric material is injected into the mold cavity 63 by known feeding systems shown schematically at 54, 74 and 60. The shapes of the molten material injected, for example, a layer of clear polymer material 84 correspond to the outer class A surface as shown in the embodiment of Figure 6. A Once the clear polymer layer is injected it remains with the cover 42. The molding press is opened and the cover 42 is returned to the press following the change of locations of the system of holes and of known ejection pistons. The cover of the mold 42 is then closed against the core member with smaller volume 50 with the injection molded material 84 remaining therein as shown in Figure 10. The mold cavity is partially filled with the layer of material 84. and the space of the remaining cavity 65 is then filled with injection molded polymeric material, such as a layer of material 86 of clear polymer material having particles of material that reflects light therein. Again the molding press is opened and the mold cover 42 is repositioned in a rotating manner and then closed against the core member with a still smaller volume 52 while the layers molded by injection on the pre-tool 84, 86 they remain in the cover of the mold 42 following the inversion of places of the holes and of the ejection pins.

The cover of the mold 42 is then placed inside the molding press 32 with the layers of injection molded material 84, 86 remaining therein as shown in Figure 11. The cavity of the mold 67 is partially filled with the layers of the mold. material 84, 86 and the remaining space is filled with injection molded polymer material such as the material layer 88 of clear polymer material having pigment or color particles therein. The molding press is opened and the material layers 84, 86, 88 are then removed from the mold cover 42 by hydraulically actuated ejector pins as a unit-formed part on the tool. These arrangements allow a wide variety of products to be produced by the duplication of the tool assemblies it must be understood that the tools shown schematically are what is required for a part with three layers of polymeric material injection molded with a perimeter profile substantially congruent. For parts with two or one layer of such polymeric injection molded material, the number of cores and presses can be reduced by the same number. By practicing the invention to obtain a class A surface in the product, the cover cavity is polished. Three jets of polymer are directed to the cavity as it progresses progressively with respect to the core sections of the progressively smaller mass (to specify a mold cavity with a progressively larger volume while retaining congruent perimeters). Suitable epoxy ejectors are provided in conjunction with the coating and suitable holes are provided in the mold section to direct the polymeric material into the mold cavity during sequential firings of the material in the mold cavity. All polymeric injection molded materials are suitable for the various layers including both thermoplastic and thermoset materials. Suitable materials for imparting color to the products to match the adjacent parts of a vehicle include any organic or inorganic pigment or ink of any kind or variety as is well known to those skilled in the art. Suitable types of light reflecting material to impart brightness to a layer include mica flakes or any other suitable material that reflects light. The article, apparatus and method of the present invention is especially suitable for the manufacture of injection molded parts of multiple layers in tool for use in any automotive or other application and include products such as door panels, consoles, shock panels for luggage and similar and for Manufacturing in the field of automotive exterior trim components such as tire covers, bumper dash, exterior door panels, rims and the like. The process also applies to the manufacture of other colored plastic composite items including but not limited to luggage for housing and electronic equipment for housing. Variations and modifications are possible without departing from the scope and spirit of the present invention as defined in the appended claims.

Claims (30)

1. CLAIMS 1. A colored plastic composite molded into an injection mold including a coating with improved finishing surface on the composite, characterized in that it comprises injection molded polymeric material and a layer of injection molded material formed directly against the coating material of the injection molded material.
2. 2. A colored plastic composite molded into an injection mold including a coating with improved finishing surface on the composite, characterized in that it comprises a single layer having a coating with an injection finishing surface of the composite and said single layer comprises material polymer injection molded, having pigments or color inks and embedded particles that reflect the light therein to change the effect of the color of said pigments or inks when the composite has been viewed at different angles, and the single layer has the appearance of the colored material improved by the finished surface coating.
3. 3. The colored plastic compound according to claim 2, characterized in that said coating of the finishing surface is opaque.
4. 4. The color plastic compound in accordance with claim 2, characterized in that the coating of the finishing surface is colored.
5. 5. The colored plastic composite according to claim 2, characterized in that the coating of the finishing surface is a clear polymeric material.
6. 6. A colored plastic composite having a first and second injection molded layers placed one on top of the other to form a base layer and an upper layer covering the base layer and wherein the top layer constitutes a surface finish coating improved of the compound characterized in that: the base layer comprising injection molded polymeric material having pigments or colored inks mixed therein; the top layer comprises injection molded polymeric material with or without embedded particles that reflect light therein to change the color effect of the pigments or color inks when the composite has been viewed from different angles.
7. 7. A colored plastic composite having first and second injection molded layers placed one on top of the other to form a base layer and an upper layer covering the base layer, in direct contact therewith and wherein the top layer it constitutes a coating of improved finishing surface of the compound characterized in that: the base layer comprises injection molded polymeric material having particles mixed therein from the group consisting of: colored pigments or inks; and embedded particles that reflect the light in it; and a top layer of injection molded polymeric material to protect the base layer.
8. 8. A colored plastic composite having first and second injection molded layers placed one on top of the other to form a base layer and an upper layer covering the base layer in direct contact therewith and wherein the top layer it constitutes an improved finish surface coating of the composite, characterized in that: the base layer comprises an injection molded polymeric material having mixed particles therein comprising pigments or color inks and embedded particles that reflect light therein; and an upper layer of clear polymeric material injection molded to protect the base base layer.
9. 9. A colored plastic compound that has a base layer, an intermediate layer and an upper layer that covers the base layer and the intermediate layer and where the top layer constitutes an improved surface finish coating of the composite, characterized in that: the base layer comprises injection molded polymeric material having pigments or colored inks mixed therein; the intermediate layer comprises injection molded polymeric material in direct contact with said base layer and has particles embedded therein that reflect light to change the color effect of the pigments or color inks when the composite is viewed from different angles; the top layer comprises injection molded polymer material in direct contact with the intermediate layer.
10. 10. The colored plastic composite according to claim 9, characterized in that the protective top layer is opaque.
11. 11. The colored plastic composite according to claim 9, characterized in that the upper protective layer is colored.
12. 12. The colored plastic composite according to claim 9, characterized in that the upper protective layer is of clear polymeric material.
13. 13. The colored plastic composite according to claim 9, characterized in that the layer Top protective has a shiny outer surface.
14. The colored plastic composite according to claim 2, characterized in that the coating of the finishing surface is a clear polymeric material having a bright outer surface.
15. A process for the manufacture of a multi-layer composite product of injection molded plastic characterized in that it comprises providing a movable mold part and a plurality of stationary mold parts of a congruent perimeter shape; sequentially moving the movable mold part with respect to the stationary mold parts to form one or more mold cavities of progressively greater capacity and injecting at least one layer of polymer material into one of the mold cavities to produce a color appearance on the exposed surface of the composite product and producing a coating surface congruent with at least one layer to improve the appearance of at least one layer of polymeric material.
16. 16. A process for manufacturing a composite product of multiple layers of injection molded plastic characterized in that it comprises providing a movable mold part and a plurality of stationary mold parts of congruent perimeter shape; move the movable mold part sequentially with respect to the stationary mold parts to form a plurality of mold cavities of progressively greater capacity and congruent perimeters; injecting a first layer of colored polymeric material into one of the cavities of the mold: injecting a second layer of polymeric material into another of the mold cavities to coat the first layer of polymeric material and to improve the appearance of the color of the same.
17. 17. The process in accordance with the claim 16, characterized in that it further comprises providing polymeric material having pigments or color inks mixed therein and injecting them as the first layer of polymeric material.
18. 18. The process in accordance with the claim 16, characterized in that it further comprises providing polymeric material having embedded particles that reflect the light therein and injecting them as one of the layers of material in one of the cavities of the mold.
19. 19. The process in accordance with the claim 16, characterized in that it further comprises injecting polymeric material having either pigments or colored inks and embedded particles that reflect light therein into one of the mold cavities.
20. 20. The process in accordance with the claim 16, characterized in that it further comprises injecting polymeric material with color pigments or inks into one of the cavities and thereafter injecting the polymeric material with particles that reflect light therein to change the color effect of the pigments or dummies when the compound is seen from different angles.
21. 21. The process according to claim 16, characterized in that it further comprises injecting clear polymeric material into another of the mold cavities to coat the polymeric material in one of the mold cavities.
22. 22. The process according to claim 16, characterized in that it further comprises injecting a coating of polymeric material into another of the cavities of the mold to coat the first layer of polymeric material in one of the cavities of the mold; and injecting polymeric material having colored pigments or inks into one of the mold cavities to form a first layer of material;
23. 23. The process in accordance with the claim 16, characterized in that it includes providing one or more rotating mold halves and providing more than one section of the fixed mold and providing a progressively greater capacity of the mold cavities by varying the size of the stationary mold sections.
24. 24. The process according to claim 23, characterized in that it includes providing the rotating mold halves and the stationary mold sections respectively as mold covers and mold cores.
25. 25. The process in accordance with the claim 23, characterized in that it includes the steps of maintaining the material injected into one of the mold cavities in one of the covers and rotating one of the covers and moving it towards a second core to form a second mold cavity to inject additional material against the material previously deposited on the deck.
26. 26. An injection molded machine sequentially operated in multiple layers characterized in that it comprises a movable mold section and more than one fixed mold section of congruent perimeter shape; the movable mold section selectively closed with respect to more than one stationary mold sections either more than one of the sections of the movable mold or more than one fixed mold section which are of a progressively smaller mass to provide a progressively greater capacity to the cavities of the mold, when the section of the mobile mold is selectively closed with respect to more than one sections of the stationary mold.
27. 27. The injection molding apparatus sequentially operated in multiple stages in accordance with claim 26 characterized in that the section of the mobile mold is carried on a rotating thick plate.
28. The sequentially operated multistage injection molding apparatus according to claim 26, characterized in that said movable mold section is a mold cover defining a mold cavity and the fixed mold section is a mold core.
29. 29. The sequentially sequentially operated multi-stage injection molding apparatus according to claim 26, characterized in that the movable mold section is a core of the mold and the fixed mold section is a mold cover.
30. 30. The sequentially sequentially operated multi-stage injection molded apparatus according to claim 26, characterized in that the rotating mold section is a mold cover having a polished inner surface and the stationary mold sections are mold cores.