Methods and systems for the preparation of molded plastic articles having a structural barrier layer

A co-injection molded multi-layer plastic article comprising:

• an inner layer comprising a first polymeric material;
• an outer layer comprising the first polymeric material;
• and
• an interior core layer comprising a second polymeric material, disposed between the inner layer and the outer layer, and configured to intentionally form a cohesion member structurally interlocking the interior layer to the inner layer, to the outer layer, or to both.

A system for forming a multi-layer molded plastic article having a cohesion member, the system comprising:

• a mold having a plurality of cavities to mold a plurality of multi-layered plastic articles;
• a first material source to supply a first polymeric material for use in forming at least one layer of each of the plurality of multi-layered plastic articles;
• a second material source to supply a second polymeric material for use in forming at least one layer of each of the plurality of multi-layered plastic articles;
• a plurality of nozzles in communication with a portion of the mold to inject the first and second polymeric materials into each of the plurality of cavities, each nozzle configured to intentionally form a composite stream including an inner stream comprising a first material, an annular outer stream comprising the first material, and an annular interior core stream comprising a second material between the inner stream and the outer stream, each nozzle is further configured for adjustment of a volumetric ratio of the of the inner stream to the outer stream in the composite stream flow ejected from the nozzle;
• a first set of flow channels configured to distribute the first polymeric material from the first material source to each of the plurality of nozzles;
• a second set of flow channels configured to distribute the second polymeric material from the second material source to each of the plurality of nozzles;
• and
• a processor programmed to, during ejection of the composite streams from the nozzles into the plurality of cavities, adjust a volumetric ratio of the inner stream to the outer stream in the composite stream flow ejected from the nozzle, to intentionally form the cohesion member from the interior core stream that structurally interlocks an interior layer of the resulting molded plastic article formed from the interior core stream with an inner layer of the resulting molded plastic article formed from the inner stream, with an outer layer of the resulting molded plastic article formed from the outer stream, or with both.

A computer-readable medium storing computer executable instructions for co-extruding a plurality of polymeric plastic material streams to produce a resulting multi-layer molded plastic article having a cohesion member, the instructions comprising instructions for:

• forming a combined polymeric plastic stream in an injection nozzle, the combined stream comprising an interior core stream of a first polymeric material encased by an inner stream of a second polymeric material and an outer stream of the second polymeric material;
• injecting the combined stream into a mold cavity;
• and
• adjusting a volumetric flow ratio of the inner stream to the outer stream during injection of the combined stream into the mold cavity to intentionally form a cohesion member from the interior core stream that structurally interlocks an interior layer of the resulting molded plastic article formed from the interior core stream with an inner layer of the resulting molded plastic article formed from the inner stream, with an outer layer of the resulting molded plastic article formed from the outer stream, or with both.