Jointed linkage system

  • US 6,932,669 B2
  • Filed: 06/11/2003
  • Issued: 08/23/2005
  • Est. Priority Date: 09/19/2000
  • Status: Expired due to Fees
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First Claim
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1. A jointed linkage support system made by a method comprising the steps of:

  • providing a mold with a series of individual communicating cavities, a first set of the individual cavities configured to receive a first part, each of the first parts having a first contour, and a second, set of the individual cavities configured to form a second part, each of the second parts having a second contour, with the individual cavities of the first set positioned such that a plurality of individual cavities of the first set alternate with a plurality of individual cavities of the second set, and wherein at least one of the cavities of the first set is bisected by a plane of symmetry between the two adjacent cavities of the second set;

    marking a plurality of the first parts from a first material having a first melting point;

    placing the first parts in the first set of cavities with portions of the first parts extending into the second set of cavities;

    introducing into the second set of cavities a second material having a second melting point which is lower than the first melting point to form the second part, wherein the second material is introduced into the second set of cavities at a temperature that is equal to or higher than the second melting point and lower than the first melting point;

    allowing the second material to cool in the second cavities to form a plurality of movable joints with the portions of the first parts which extend into the second set of cavities, thereby molding a jointed linkage support system in which the first parts pivot with respect to the second parts without any of the second parts engaging an adjacent one of the second parts;

    providing the mold with a third set of cavities;

    marking a switch assembly material having a melting point greater than the second melting point;

    placing the switch assembly in a cavity of the third set of cavities with a portion of the switch assembly extending into a cavity of the second set of cavities before the second material is introduced into the second set of cavities; and

    introducing the second material into the second set of cavities to form movable joints with the first parts and the switch assembly.

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