Method for insert molding glass or an inorganic material

• US 8,514,494 B2
• Filed: 01/22/2010
• Issued: 08/20/2013
• Est. Priority Date: 05/15/2009
• Status: Active Grant

• Current Assignee: HI-P Singapore Pte Limited
• Original Assignee: HI-P International Limited (YHT Venture Pte Ltd.)
• Inventors: Alcazar, Ross, Meng, Jie
• Primary Examiner(s): HASAN, MOHAMMED A
• Application Number:
  US12/736,969
• Publication Number:
  US 20120044590A1
• Time in Patent Office: 1,306 Days
• Field of Search: 359/642, 359694-830, 264 11- 27
• US Class Current: 359/642
• CPC Class Codes: B29C 45/14434 Coating brittle material, e.g. glass B29C45/14377, B29C45/14418 take precedence
• CPC Class Codes: B29C 45/14467 Joining articles or parts of a single article B29C45/14377, B29C45/14385, B29C45/14581, B29C45/14614 and B29C45/006 take precedence
• CPC Class Codes: B29L 2031/3431 Telephones, Earphones
• CPC Class Codes: H04M 1/0266 for a display module assembly
• CPC Class Codes: H04M 1/0283 for providing a decorative aspect, e.g. customization of casings, exchangeable faceplate

Abstract

The present invention relates to insert molding a glass lens or an inorganic material into a front housing unit. The glass lens or an inorganic material is aligned within the front housing unit so that it lies within the inside of the front housing unit. A thermobond adhesive or an adhesive promoter is applied onto the glass lens or the inorganic material. During molding a molten resin is injected into the space formed between the glass lens or the inorganic material and the front housing unit and flows around the glass lens or the inorganic material activating and liquefying the adhesive promoter or the thermobond adhesive and forming an insert molded part.

Claims

1. A process for producing an insert molded part comprising the steps of:

providing a glass lens;

providing a front housing unit;

providing a thermobond adhesive;

applying thermobond adhesive onto the glass lens;

inserting the glass lens into the front housing unit, aligning the glass lens with the front housing unit such that the glass lens lies within an inside area of the front housing unit and defines a space there between;

injecting a molten resin, during an insert molding process, into the space formed between the glass lens and the front housing unit;

wherein the molten resin flows around the glass lens, the molten resin activates and liquefies the thermobond adhesive that is applied onto the glass lens and forms an insert molded part, and when the insert molded part is ejected and cooled, the thermobond adhesive permanently bonds the glass lens and the cooled resin.

2. An insert molded part manufactured by the process of claim 1.

3. A process for producing a glass insert molding housing unit comprising the steps of:

providing a glass lens;

providing a front housing unit in the shape of the glass lens;

applying one of an adhesive promoter and a thermobond adhesive to the glass lens;

inserting the glass lens into the front housing unit, aligning the glass lens with the front housing unit such that the glass lens lies within an inside area of the front housing unit and defines a space there between;

injecting a molten resin, during a glass insert molding process, into the space formed between the glass lens and the front housing unit;

wherein the molten resin flows around the glass lens and forms a glass insert molding housing unit, the molten resin activating and liquefying the one of the adhesive promoter and the thermobond adhesive to create heat and pressure, and when the resin hardens, the front housing unit encapsulates the glass lens and the glass lens permanently bonds within the front housing unit.

4. A glass insert molding housing unit manufactured by the process of claim 3.

5. A process for producing an insert molded part comprising the steps of:

providing an inorganic material;

providing a front housing unit;

providing a thermobond adhesive;

applying thermobond adhesive onto the inorganic material;

inserting the inorganic material into the front housing unit, aligning the inorganic material with the front housing unit such that the inorganic material lies within the inside of the front housing unit;

injecting a molten resin, during an insert molding process, into space formed by the inorganic material and the front housing unit;

wherein the molten resin flows around the inorganic material, the molten resin activates and liquefies the thermobond adhesive that is applied onto the inorganic material and forms an insert molded part, and when the insert molded part is ejected and cooled, the thermobond adhesive permanently bonds the inorganic material and the resin.

6. The process according to claim 5 wherein the inorganic material is a ceramic.

7. The process according to claim 5 wherein the inorganic material is a metal.

8. The process according to claim 5 wherein the inorganic material is a fabric.

9. An insert molded part manufactured by the process of claim 5.

10. An insert molded part comprising:

a front housing unit;

a glass lens disposed inside of the front housing unit;

a thermobond adhesive applied onto the glass lens;

a resin formed between the front housing unit and the glass lens;

wherein the thermobond adhesive, activated by molten resin during molding, makes direct contact with and permanently bonds to the glass lens and the resin.