Applicator and method for in-mold coating

Abstract

An in-mold applicator and method for spraying a coating on difficult-to-reach surfaces of a mold is disclosed. The applicator includes a spray head and a base portion at an oblique angle to each other. The outer dimensions of the body portion and the spray head are sufficiently small so that taken in combination with the oblique angle, the applicator and method can enhance the spraying of the coating to difficult-to-reach surfaces within the mold.

1 . An in-mold applicator to spray a coating on a first difficult-to-reach undercut surface of a mold, the in-mold applicator comprising: 
 a body portion and a spray head extending at an oblique angle with respect to the body portion, the body portion and spray head having outer dimensions that are sufficiently small in combination with the oblique angle to enhance the spraying of the coating to the first undercut surface;    each of the spray head and the body portion having a central passageway for delivering a liquid medium and an outer passageway surrounding the central passageway for delivering a gaseous medium;    a liquid medium head joining the central passageways in liquid medium flow relationship proximate the oblique angle; and    a closable and operable liquid medium valve within the liquid medium head for selectively controlling a sufficient flow of liquid medium through the liquid medium head for atomization with the delivered gaseous medium.    
     
     
         2 . The in-mold applicator of  claim 1  wherein the liquid medium is a mold release agent and the gaseous medium is air.  
     
     
         3 . The in-mold applicator of  claim 1  further comprising an adaptor for operatively connecting the in-mold applicator to a robot used to operate the applicator, the adaptor having three valves operable to supply respectively the liquid and gaseous mediums necessary to apply the coating on the first undercut surface, the three valves including a first valve providing the gaseous medium to the outer passageway of the body portion, a second valve providing the liquid medium to the central passageway of the body portion, and a third valve for actuating the liquid medium valve.  
     
     
         4 . The in-mold applicator of  claim 3  wherein the liquid medium valve is a needle valve which controls the flow of liquid medium through the liquid medium head and the central passageway at the oblique angle.  
     
     
         5 . The in-mold applicator of  claim 1  further comprising an additional spray head that is threadably connectable with the body portion, wherein the spray head is threadably connected to the body portion such that the spray head is exchangeable with the additional spray head, the additional spray head being connectable with the body portion to establish a different oblique angle with the body portion.  
     
     
         6 . The in-mold applicator of  claim 1  further comprising an additional spray head that is threadably connectable with the body portion, wherein the spray head is threadably connected to the body portion such that the spray head is exchangeable with the additional spray head, and wherein the additional spray head is configured to coat a second difficult-to-reach undercut surface that is different from the first difficult-to-reach undercut surface.  
     
     
         7 . An in-mold applicator for spraying a coating on difficult-to-reach surfaces of a mold, the in-mold applicator comprising: 
 a spray head and body portion at an oblique angle to each other, the body portion and spray head having outer dimensions that are sufficiently small in combination with the oblique angle to enhance the spraying of the coating onto the difficult-to-reach surfaces of the mold.    
     
     
         8 . An in-mold applicator to spray a coating on a first difficult-to-reach undercut surface of a mold which is not directly visible from an external view of the mold, the applicator comprising: 
 a body section and a spray head, the spray head having an angled body portion and a non-angled portion such that the spray head defines a fixed oblique angle between the angled and non-angled portions, the spray head having threads on the non-angled portion for threadably securing to threads on the body section, the body section and spray head having outer dimensions sufficiently small in combination with the oblique angle to enhance spraying of the coating onto the difficult-to-reach surfaces of the mold, the body section and spray head each including a central passageway for delivering a liquid medium and an outer passageway surrounding the central passageway for delivering a gaseous medium, the spray head further including a spray cap secured to an outlet end of the spray head by a spray cap lock, the spray cap lock having threads for securing to threads on the spray head, the spray cap lock defining an outer boundary of the spray head.    
     
     
         9 . The applicator of  claim 8  wherein a fluid may be atomized by providing the gaseous medium to the outer passageway and the liquid medium to the central passageway of the body portion such that the liquid medium collides with the gaseous medium inside the outer boundary defined by the spray cap lock.  
     
     
         10 . The applicator of  claim 9  wherein the spray head may be positioned to spray the atomized fluid within the mold in a head-on position sufficient to squarely spray the atomized fluid onto the mold and the first undercut surface.