Insert molded parts and methods for forming the same
First Claim
1. A method for forming a composite part having an insert and a molded piece, the method comprising:
- securing the insert within a mold using a support mold, the insert having a first surface area and a second surface area, wherein the support mold covers the second surface area;
forming a first portion of the molded piece on the first surface area by injecting a first resinous material into the mold and onto the first surface area;
removing the support mold from the insert, thereby exposing the second surface area of the insert via a recess within the first portion; and
forming a second portion of the molded piece by injecting a second resinous material through a gate portion of the mold into the recess and onto the second surface area, wherein the gate portion forms an indentation within molded piece.
1 Assignment
0 Petitions
Accused Products
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.
23 Citations
20 Claims
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1. A method for forming a composite part having an insert and a molded piece, the method comprising:
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securing the insert within a mold using a support mold, the insert having a first surface area and a second surface area, wherein the support mold covers the second surface area; forming a first portion of the molded piece on the first surface area by injecting a first resinous material into the mold and onto the first surface area; removing the support mold from the insert, thereby exposing the second surface area of the insert via a recess within the first portion; and forming a second portion of the molded piece by injecting a second resinous material through a gate portion of the mold into the recess and onto the second surface area, wherein the gate portion forms an indentation within molded piece. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A composite part, comprising:
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an insert having a first surface area and a second surface area; and a molded piece formed using an injection molding process, the molded piece comprising; a first portion disposed on the first surface area of the insert, the first portion including a recess that provides access to the second surface area of the insert, a second portion disposed on the second surface area of the insert by way of the recess, and an indentation disposed within the first portion, the indentation formed during the injection molding process. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15, 16)
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17. An electronic device, comprising:
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a printed circuit board having a first surface area and a second surface area; and a molded piece at least partially encasing the printed circuit board therein, the molded piece formed using an injection molding process, the molded piece comprising; a first portion disposed on the first surface area, the first portion including a recess that provides access to the second surface area of the printed circuit board, a second portion disposed on the second surface area via the recess, and an indentation disposed within the molded piece, the indentation formed during the injection molding process. - View Dependent Claims (18, 19, 20)
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Specification