Continuous molded plastic components or assemblies

• US 5,967,841 A
• Filed: 03/06/1998
• Issued: 10/19/1999
• Est. Priority Date: 07/05/1995
• Status: Expired due to Term

• Current Assignee: Autosplice Systems, Inc.
• Original Assignee: Autosplice Systems, Inc.
• Inventors: Bogursky, Robert M., Bianca, Giuseppe
• Primary Examiner(s): NGUYEN, KHIEM M
• Application Number:
  US09/036,083
• Time in Patent Office: 592 Days
• Field of Search: 439/78, 439/590, 439/885, 439/937, 29/842, 29/883, 29/884
• US Class Current: 439/590
• CPC Class Codes: B29C 45/0003 of successively moulded portions rigidly joined to each other
• CPC Class Codes: B29C 45/14 incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles B29C45/1671 takes precedence
• CPC Class Codes: H01R 12/716 Coupling device provided on the PCB
• CPC Class Codes: H01R 43/24 Assembling by moulding on contact members
• CPC Class Codes: H01R 9/2408 Modular blocks H01R9/26 takes precedence
• CPC Class Codes: H05K 3/306 Lead-in-hole components, e.g. affixing or retention before soldering, spacing means H05K3/32 takes precedence
• CPC Class Codes: Y10S 439/937 Plural insulators in strip form

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.

Claims

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.

2. The strip of claim 1, wherein the middle units each have a hole for receiving an electrical or mechanical component, the integrally-molded and projecting portions of the first and second end units lacking a hole.

3. The strip of claim 2, wherein the holes in the middle units have a given pitch, further comprising a plurality of spaced approximately in-line electrical or mechanical components each mounted in one of the holes in the middle units along substantially the length of said elongated strip, whereby a desired pitch distance between the mounted components is preserved within each segment and one or more individual units can be severed from the strip as desired.

4. The strip of claim 1, further comprising notches between only some of the units.

5. In combination with the strip of claim 1, a reel, the strip being wound up on the reel.

6. The strip of claim 1, wherein the middle units are usable for receiving or as an electrical or mechanical components and the integrally-molded and projecting portions of the first and second end units are unusable for receiving or as an electrical or mechanical components.

7. 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) 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.

8. The strip of claim 7, wherein at least some of the units are constituted of a compound plastic.

9. The strip of claim 7, wherein at least some of the units are constituted of a fiber-reinforced plastic.

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:

(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.

11. The strip of claim 10, further comprising a reel, said elongated strip of insulating material being wound up on the reel.

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:

(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.

13. The method of claim 12, wherein the projecting portion of the second end unit is configured as a tongue with the second hole.

14. 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 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.

15. The strip of claim 14, wherein the middle units each have a hole of given size for receiving an electrical or mechanical component, and the interlocking units each also have a hole of the given size for receiving an electrical or mechanical component.

16. The strip of claim 15, wherein the holes in the middle units and interlocking units have a given pitch, further comprising a plurality of spaced approximately in-line electrical or mechanical components each mounted in one of the holes in the middle and interlocking units along substantially the length of said elongated strip, whereby a desired pitch distance between the mounted components is preserved within the consecutive series of segments and one or more individual units can be severed from the strip as desired.

17. The strip of claim 14, further comprising notches between the units positioned so as to allow each unit when severed at a notch to form a complete unit without any excess removable scrap.

18. A continuous strip as claimed in claim 14, wherein the middle units each have a hole of given size for receiving an electrical or mechanical component, the projecting portion also has at least one component-receiving hole for receiving an electrical or mechanical component, the integrally-molded portion allowing access by the electrical or mechanical component to the at least one component-receiving hole in the projecting portion.

19. A continuous strip as claimed in claim 18, wherein the component-receiving holes are evenly spaced and a desired pitch distance between the mounted components is preserved.

20. A continuous strip as claimed in claim 18, further comprising a plurality of spaced approximately in-line electrical or mechanical components in the form of electrical pins each mounted in one of the holes in the middle and interlocking units along substantially the length of said elongated strip, whereby a desired pitch distance between the mounted pins is preserved within the consecutive series of segments and one or more individual units as separable pin headers can be severed from the strip as desired.

21. A continuous strip as claimed in claim 20, wherein the separable header units are separated by severance means.

22. In combination with the strip of claim 14, a reel, the strip being wound up on the reel.

23. A continuous strip of separable units comprising 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 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.

24. A continuous strip of separable molded component units as claimed in claim 23, wherein the projecting portion of the trailing end unit of each segment having multiple holes or recessed portions filled with molded material of the integrally-molded portion of the leading end unit of the adjacent segment.