Continuous molded plastic components or assemblies
First Claim
Patent Images
1. A continuous strip of separable units containing spaced electrical or mechanical components comprising:
- (a) a consecutive series of at least three injection-molded segments of moldable material including end segments,(b) each segment comprising a consecutive series of integrally connected but severable units comprised of first leading and second trailing end units and a plurality of middle units between the end units, said middle units each being of moldable material and separated along their length from each other,(c) except for the end segments, one of the first and second end units of each segment having a portion integrally-molded with a projecting portion of the other of the first and second end units of the adjacent segment whereby successive segments are integrally coupled by their respective integrally-molded and projecting portions of the first and second end units and with the projecting portion of the other of the first and second end units of each segment having had a hole or recessed portion filled with molded material of the integrally-molded portion of the one of the first and second end units of the adjacent segment, said projecting portion of the other end unit comprising a rearwardly projecting portion extending approximately in line with the strip,(d) the integrally coupled segments forming an elongated strip of molded units,(e) each of the middle units being similarly configured, the integrally-molded and projecting portions of the first and second end units having a configuration different from that of the middle units.
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Accused Products
Abstract
A continuous electrical connector or component part of plastic or metal manufactured by injection molding of axial segments in sequence. A novel in-line interlocking structure is provided for interlocking adjacent segments. The interlocking structure comprises overmolded end units wherein the next overmolded part fills in a hole or recess left in the previous molded part. Electrical or mechanical parts may, if desired, be simultaneously incorporated in the units of each segment during the molding process.
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Citations
24 Claims
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1. A continuous strip of separable units containing spaced electrical or mechanical components comprising:
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(a) a consecutive series of at least three injection-molded segments of moldable material including end segments, (b) each segment comprising a consecutive series of integrally connected but severable units comprised of first leading and second trailing end units and a plurality of middle units between the end units, said middle units each being of moldable material and separated along their length from each other, (c) except for the end segments, one of the first and second end units of each segment having a portion integrally-molded with a projecting portion of the other of the first and second end units of the adjacent segment whereby successive segments are integrally coupled by their respective integrally-molded and projecting portions of the first and second end units and with the projecting portion of the other of the first and second end units of each segment having had a hole or recessed portion filled with molded material of the integrally-molded portion of the one of the first and second end units of the adjacent segment, said projecting portion of the other end unit comprising a rearwardly projecting portion extending approximately in line with the strip, (d) the integrally coupled segments forming an elongated strip of molded units, (e) each of the middle units being similarly configured, the integrally-molded and projecting portions of the first and second end units having a configuration different from that of the middle units. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A continuous strip of separable units containing spaced electrical or mechanical components comprising:
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(a) a consecutive series of at least three injection-molded segments of moldable material including end segments, (b) each segment comprising a consecutive series of integrally connected but severable units comprised of first leading and second trailing end units and a plurality of middle units between the end units, said middle units each being of moldable material and separated along their length from each other, (c) except for the end segments, one of the first and second end units of each segment having a portion integrally-molded with a projecting portion of the other of the first and second end units of the adjacent segment whereby successive segments are integrally coupled by their respective integrally-molded and projecting portions of the first and second end units and with the projecting portion of the other of the first and second end units of each segment having had a hole or recessed portion filled with molded material of the integrally-molded portion of the one of the first and second end units of the adjacent segment, said projecting portion of the other end unit comprising a rearwardly projecting portion extending approximately in line with the strip, (d) the integrally coupled segments forming an elongated strip of molded units, (e) at least some of the units being constituted of electrically insulating plastic, (f) at least some of the units being constituted of electrically conductive plastic. - View Dependent Claims (8, 9)
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10. A continuous elongated injection-molded strip of moldable material containing a plurality of spaced approximately in-line components along substantially the length of said strip, comprising:
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(a) a consecutive series of injection-molded segments of moldable material including end segments, (b) each segment comprising a consecutive series of connected integral components comprised of first leading and second trailing end units and a plurality of middle units between the end units, said middle units each being of moldable material and separated along their length from each other, each of some of said middle units having a first hole, the first hole of each of the middle units extending parallel to one another and transverse to the elongated strip, (c) except for the end segments, one of the first and second end units of each segment having a portion overmolding a projecting portion of the other of the first and second end units of the adjacent segment whereby successive segments are integrally coupled by their respective overmolded and projecting portions of the second and first end units and with the projecting portion of the other of the first and second end units of each segment having had a second hole filled with a molded crossbar of the other of the first and second end units of the adjacent segment, the second hole of each of the other of the first and second end units extending substantially parallel to and spaced from the first holes. - View Dependent Claims (11)
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12. A method of forming a continuous elongated injection-molded strip of moldable material comprising a plurality of spaced approximately in-line components, comprising the steps:
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(a) providing a mold shaped to form one segment of moldable material, said one segment comprising a consecutive series of connected, integral units comprised of first and second end units and a plurality of middle units between the end units, at least the second end unit comprising a projecting portion approximately in line with the strip, (b) providing a core pin positioned to form a hole in the projecting portion, (c) introducing into the mold molten material and allowing same to cool to form a first segment of material with each of some of said middle units having a first hole, the first hole of each of the middle units extending parallel to one another and transverse to the elongated strip, the second end unit comprising the projecting portion containing a second hole with the second hole of each of the other of the first and second end units extending substantially parallel to and spaced from the first holes, (d) removing from the mold the first segment and reinserting the projecting portion of the second end unit of the first segment in the mold, (e) introducing into the mold molten material and allowing same to cool to form a second segment with first and second end units and middle units with each of some of the middle units having a third hole, the third hole of each of the middle units extending parallel to the first and second holes, and with the first end unit of the second segment comprising a part overmolded with the projecting portion of the second end unit of the first segment and with the second hole in the projecting portion filled with a crossbar of molded material whereby the first and second segments are integrally coupled by the overmolded projecting portion, (f) repeating step (d) with respect to the second segment and step (e) to form a third segment integrally coupled with the second segment, and so on, whereby successive segments can be formed and integrally coupled to form an elongated strip of moldable material. - View Dependent Claims (13)
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14. A continuous strip of separable units containing spaced electrical or mechanical components comprising:
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(a) a consecutive series of at least three injection-molded segments of moldable material including end segments, (b) each segment comprising a consecutive series of integrally-connected but severable units comprised of first leading and second trailing partially-formed end units and a plurality of completely-formed middle units between the end units, said middle and end units each being of moldable material and separated along their length from each other, (c) except for the end segments, one of the first and second end units of each segment having a portion integrally-molded with a projecting portion of the other of the first and second end units of the adjacent segment to form a completely-formed interlocking unit whereby successive segments are integrally coupled by their respective interlocking unit and with the projecting portion of the other of the first and second end units of each segment having had a hole or recessed portion filled with molded material of the integrally-molded portion of the one of the first and second end units of the adjacent segment, said projecting portion of the other end unit being rearwardly projecting and extending approximately in line with the strip, (d) the integrally coupled segments forming an elongated strip of molded separable completely-formed units, (e) each of the middle units being similarly configured, the integrally-molded projecting portions of the first and second end units forming the interlocking units having a configuration substantially the same as that of the middle units, whereby each of the middle units and each of the interlocking units are usable when severed from the strip for receiving an electrical or mechanical component or for use as an electrical or mechanical component. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22)
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23. A continuous strip of separable units comprising spaced electrical or mechanical components comprising:
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(a) a consecutive series of at least three injection-molded segments of moldable material including end segments, (b) each segment comprising a consecutive series of integrally-connected but severable units comprised of first leading and second trailing end units and a plurality of middle units between the end units, said middle units each being of moldable material and separated along their length from each other, (c) except for the end segments, one of the first and second end units of each segment having a portion integrally-molded with a projecting portion of the other of the first and second end units of the adjacent segment whereby successive segments are integrally coupled by their respective integrally-molded projecting portions of the first and second end units and with the projecting portion of the other of the first and second end units of each segment having had a hole or recessed portion filled with molded material of the integrally-molded portion of the one of the first and second end units of the adjacent segment, said projecting portion of the other end unit comprising a rearwardly projecting portion extending approximately in line with the strip, each of the projecting portions being incorporated into and becoming a part of the adjacent unit, (d) the integrally coupled segments forming an elongated strip of substantially identical molded units, (e) severance means located at each of the integrally molded portions, whereby one or more substantially-identical molded units can be separated from the continuous strip in a scrapless process. - View Dependent Claims (24)
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Specification