INSERT MOLDED PARTS AND METHODS FOR FORMING THE SAME

• US 20150092365A1
• Filed: 12/16/2013
• Published: 04/02/2015
• Est. Priority Date: 09/30/2013
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Stanley, Craig M.
• Granted Patent: US 9,682,500 B2
• Time in Patent Office: Days
• US Class Current: 361/752
• CPC Class Codes: B29C 45/14065 Positioning or centering articles in the mould
• CPC Class Codes: B29C 45/1635 using displaceable mould parts, e.g. retractable partition between adjacent mould cavities
• CPC Class Codes: B29C 45/1671 with an insert
• CPC Class Codes: B29L 2031/3425 Printed circuits
• CPC Class Codes: Y10T 428/23 Sheet including cover or casing
• CPC Class Codes: Y10T 428/239 Complete cover or casing

Abstract

The embodiments described herein relate to insert molding methods. The methods involve partially or fully encasing an insert within a thermoplastic material, forming a composite part that includes the insert and the molded thermoplastic material. Methods described provide a number of improvements over traditional insert molding techniques. In specific embodiments, a two-shot molding process is used whereby a first shot is formed on a first portion of the insert and a second shot is formed on a second portion of the insert. The insert molding processes can be performed using a single mold during the first and second injection molding processes.

Claims

1. A method for forming a composite part having an insert and a molded portion, the method comprising:

securing the insert within a mold using at least one support mold, the insert having a first surface in contact with the support mold and an exposed second surface;

forming a first part of the molded portion by injecting a first resinous material into the mold, wherein during the injecting, the first resinous material covers the second surface of the insert;

removing the support mold from the first surface of the insert exposing the first surface of the insert and forming a recess within the first part of the molded portion; and

forming a second part of the molded portion by injecting a second resinous material into the recess and over the first surface of the insert such that the first surface and second surface of the insert are encased within the molded portion.

2. The method as recited in claim 1, wherein the first part of the molded portion and the second part of the molded portion are from the same stock of thermoplastic material.

3. The method as recited in claim 1, wherein forming the first and second parts of the molded portion comprises partially encasing the insert within the molded portion.

4. The method as recited in claim 1, wherein forming the first and second parts of the molded portion comprises substantially fully encasing the insert within the molded portion.

5. The method as recited in claim 1, wherein injecting the first resinous material comprises injecting the first resinous material through a first runner system and injecting the second resinous material comprises injecting the second resinous material through a second runner system, wherein the first runner system is different than the second runner system.

6. The method as recited in claim 1, wherein the molded portion comprises an indentation formed during formation of the molded portion.

7. The method as recited in claim 1, wherein forming the first part and the second part involves forming a watertight barrier between at least a portion of the insert and an outer environment.

8. A composite part, comprising:

an insert having a first surface and a second surface; and

a molded piece formed using an injection molding process, the molded piece comprising;

a first molded portion molded onto the second surface of the insert,

a second molded portion molded onto the first surface of the insert and onto at least a section of the first molded portion, and

an indentation disposed within the first molded portion, the indentation formed during the injection molding process.

9. The composite part as recited in claim 8, wherein the first molded portion and the second molded portion comprise the same stock of thermoplastic material.

10. The composite part as recited in claim 8, wherein the insert is partially encased within the molded piece.

11. The composite part as recited in claim 8, wherein the insert is substantially fully encased within the molded piece.

12. The composite part as recited in claim 8, wherein the composite part is part of an electronic device.

13. The composite part as recited in claim 8, wherein the insert is an electronic component.

14. The composite part as recited in claim 13, wherein the electronic component is a printed circuit board.

15. The composite part as recited in claim 8, wherein the first molded portion and the second molded portion create a watertight barrier between at least a portion of the insert and an outer environment.

16. The composite part as recited in claim 8, wherein the composite part includes two indentations formed during the injection molding process.

17. An electronic device, comprising:

a printed circuit board having a first surface and a second surface; and

a molded piece at least partially encasing the printed circuit board therein, the molded piece formed using a molding process, the molded piece comprising;

a first molded portion disposed on the second surface of the printed circuit board,

a second molded portion disposed on the first surface of the printed circuit board and disposed on at least a section of the first molded portion, and

an indentation disposed within the first molded portion, the indentation formed during the molding process.

18. The electronic device as recited in claim 17, wherein the first molded portion and the second molded portion comprise the same stock of material.

19. The electronic device as recited in claim 17, wherein the first molded piece creates a watertight barrier between at least a portion of the printed circuit board and an outer environment.

20. The electronic device as recited in claim 17, wherein the indentation is proximate the second molded portion.