Method for making a reinforced, polymeric article in a reaction injection molding system and mold for use therein

A method for making a reinforced, polymeric article having reduced surface defects in a reaction injection molding system including a mold having an injection aperture and at least one flow path which extends from the injection aperture to a closed, article-forming cavity in the mold, the at least one flow path being at least partially defined by an elongated film gate and a runner which extends along and is in fluid communication with the film gate along substantially the entire length of the film gate, the method comprising:

• injecting an amount of curable, multi-component, reaction fluid mixture including a filler through the injection aperture and along the at least one flow path wherein the amount is sufficient for the preparation of the article;
• mixing components of the fluid mixture with a plurality of flow paths which converse to a passageway of the flow stream upstream the runner after the step of injecting;
• forcing the fluid mixture to flow within the passageway initially in a first direction and then in a second direction substantially perpendicular to the first direction;
• forcing the fluid mixture to flow into and along the runner in the second direction;
• forcing the fluid mixture to flow from the runner and into the film gate and the article-forming cavity in a third direction substantially perpendicular to the second direction so that the fluid mixture enters the article-forming cavity as a laminar stream;
• and
• curing the fluid mixture within the article-forming cavity to form the reinforced polymeric article which has a substantially wave-free surface.