Method of overmolding a substrate and product made by that process

• US 20050244611A1
• Filed: 04/30/2004
• Published: 11/03/2005
• Est. Priority Date: 04/30/2004
• Status: Active Grant

• Current Assignee: Medtronic Incorporated (Medtronic Plc)
• Original Assignee: Medtronic Incorporated (Medtronic Plc)
• Inventors: Kast, John E., Peters, Charles E., Deininger, Steve T.
• Granted Patent: US 7,955,543 B2
• Time in Patent Office: Days
• US Class Current: 428/137
• CPC Class Codes: A61N 1/375 Constructional arrangements, e.g. casings
• CPC Class Codes: A61N 1/37512 Pacemakers
• CPC Class Codes: A61N 1/3758 Packaging of the components within the casing
• CPC Class Codes: B29C 2045/14893 Preventing defects relating to shrinkage of inserts or coating material
• CPC Class Codes: B29C 2045/14942 Floating inserts, e.g. injecting simultaneously onto both sides of an insert through a pair of opposed gates
• CPC Class Codes: B29C 2045/14967 Injecting through an opening of the insert
• CPC Class Codes: B29C 45/14065 Positioning or centering articles in the mould
• CPC Class Codes: B29C 45/14639 for obtaining an insulating effect, e.g. for electrical components
• CPC Class Codes: B29C 45/1671 with an insert
• CPC Class Codes: Y10T 428/24322 Composite web or sheet

Abstract

A method of overmolding a substrate having a first side and a second side and a product made by that process. A plurality of support feet are placed on the first side of the substrate. The substrate is placed in an injection mold. The mold is filled with a molding material with the molding material enveloping both the first side and the second side of the substrate. The substrate is removed having been overmolded from the injection mold.

Claims

1. A method of overmolding a substrate having a first side and a second side, comprising the steps of:

placing a plurality of support feet on said first side of said substrate;

placing said substrate in an injection mold;

filling said mold with a molding material with said molding material enveloping both said first side and said second side of said substrate; and

removing said substrate having been overmolded from said injection mold.

2. A method of overmolding as in claim 1 wherein molding material is substantially evenly distributed on said first side and said second side during said filling step.

3. A method of overmolding as in claim 2 wherein said placing a plurality of support feet step comprises molding a plurality of support feet on said first side of said substrate.

4. A method of overmolding as in claim 1 wherein said substrate has a central hub opening.

5. A method of overmolding as in claim 4 wherein said injection mold has injection openings on one side of said injection mold and wherein said molding material is injected into said mold through said injection openings.

6. A method of overmolding as in claim 5 wherein said substrate is placed in said injection mold with said first side of said substrate facing said one side of said injection mold.

7. A method of overmolding as in claim 6 wherein said molding material is distributed to said second side of said substrate through said central hub opening.

8. A method of overmolding as in claim 1 wherein said feet have a circular cross-section.

9. A method of overmolding as in claim 8 wherein molding material forms around each of said plurality of feet.

10. A method of overmolding as in claim 9 wherein said central hub opening has a circular post around which said molding material is allowed to form.

11. An overmolded substrate having a first side and a second side, comprising:

a generally planar substrate;

a plurality of support feet on said first side of said substrate; and

a molding material molded around said substrate enveloping said substrate of both said first side and said second side of said substrate.

12. An overmolded substrate as in claim 11 wherein said support feet are molded in a first molding step and said molding material is molded around said substrate in a second molding step.

13. An overmolded substrate as in claim 12 wherein molding material is substantially evenly distributed on said first side and said second side during molding;

14. An overmolded substrate as in claim 11 wherein said substrate is overmolded only from said first side of said substrate.

15. An overmolded substrate as in claim 11 wherein said substrate has a central hub opening.

16. An overmolded substrate as in claim 15 wherein said molding material is distributed to said second side of said substrate through said central hub opening.

17. An overmolded substrate as in claim 11 wherein said feet have a circular cross-section.

18. An overmolded substrate as in claim 17 wherein molding material forms around each of said plurality of feet.

19. An overmolded substrate as in claim 18 wherein said central hub opening has a circular post around which said molding material is allowed to form.

20. An overmolded substrate having a first side and a second side, comprising:

a generally planar magnetic substrate;

a coil positioned on said second side of said magnetic substrate;

a plurality of support feet on said first side of said magnetic substrate; and

a molding material molded around said substrate enveloping said magnetic substrate on both said first side and said second side of said magnetic substrate.

21. An overmolded substrate as in claim 20 wherein said support feet are molded in a first molding step and said molding material is molded around said magnetic substrate in a second molding step.

22. An overmolded substrate as in claim 21 wherein molding material is substantially evenly distributed on said first side and said second side of said magnetic substrate during molding;

23. An overmolded substrate as in claim 21 wherein said second side of said molding material is concave.

24. An overmolded substrate as in claim 20 wherein said magnetic substrate is overmolded only from said first side of said magnetic substrate.

25. An overmolded substrate as in claim 20 wherein said magnetic substrate has a central hub opening.

26. An overmolded substrate as in claim 25 wherein said molding material is distributed to said second side of said magnetic substrate through said central hub opening.

27. An overmolded substrate as in claim 20 wherein said feet have a circular cross-section.

28. An overmolded substrate as in claim 27 wherein molding material forms around each of said plurality of feet.

29. An overmolded substrate as in claim 28 wherein said central hub opening has a circular post around which said molding material is allowed to form.