In one aspect, a method of coinjection molding a multilayer article having a multi-segment internal layer is disclosed. A surface layer material is injected into a mold cavity from at least one of an inner outlet and an outer outlet of a multi-channel nozzle. An internal layer material is intermittently injected into the mold cavity from an intermediate outlet of the multi-channel nozzle that is between the inner and outer outlets. The intermittent injecting of the internal layer material is controlled, at least in part, by intermittent opening and closing of the intermediate outlet. An apparatus for coinjection molding the multilayer article with the segmented internal layer is also disclosed.

In one aspect, a method of coinjection molding a multilayer article having a multi-segment internal layer is disclosed. A surface layer material is injected into a mold cavity from at least one of an inner outlet and an outer outlet of a multi-channel nozzle. An internal layer material is intermittently injected into the mold cavity from an intermediate outlet of the multi-channel nozzle that is between the inner and outer outlets. The intermittent injecting of the internal layer material is controlled, at least in part, by intermittent opening and closing of the intermediate outlet. An apparatus for coinjection molding the multilayer article with the segmented internal layer is also disclosed.

In one aspect, a method of coinjection molding a multilayer article using a coinjection nozzle having inner outlet, an outer outlet, and an intermediate outlet between the inner and outer outlets is provided. A stream of surface layer material is injected into a mold cavity from the intermediate outlet. With the injection ongoing, two streams of internal layer material are injected from the inner and outer outlets of the coinjection nozzle respectively. The two streams sandwich the stream of surface layer material and flow behind a melt front of the surface layer material. The sandwiched stream of surface layer material continues to supply the melt front with surface layer material at least until the melt front nears a distal end of the mold cavity. The resultant article is substantially or entirely encapsulated by a skin of the surface layer material and contains a high proportion of internal layer material.