Methods for molding composite polyester articles having rigid and

Abstract

Composite molded articles having relatively rigid and flexible resin regions are bonded to one another along an interfacial fusion zone. A normally solid thermoplastic polyalkylene terephthalate resin preform (which will constitute the relatively rigid region of the composite article) is placed in a mold cavity. The flexible region of the composite article is then formed by introducing a molten thermoplastic polyester elastomer resin into the mold cavity at a temperature which is greater than the melt temperature of the solid preform. The introduced thermoplastic polyester elastomer resin contacts and at least partially plasticizes a surface region of the solid preform along the interfacial bonding zone within the mold cavity to thereby cause the polyester elastomer resin to coalesce with the at least partially plasticized surface region of the polyester resin. Upon cooling and solidification, the solid preform and the polyester elastomer are fused to one another along the interfacial bonding zone.