Embodiments of the present invention generally relate to a system and method for forming a channel within a molded plastic part, and more particularly to a system and method that are configured to form a non-linear channel within a molded plastic component.
In order to form a hole or channel within a molded part, a rigid straight core pin is typically used. The pin itself is usually formed of hard steel. During a forming process, after plastic flows around the rigid core pin, the plastic cools and solidifies. When the core pin is pulled out of the part, a linear channel defined by the rigid straight core pin is formed through the solidified plastic.
In various applications, however, a non-linear channel may be desired. The rigid straight core pin is unable to form such a channel, particularly in a plastic part. Thus, in order to form a channel through such a plastic part, multiple rigid straight core pins may typically be used. For example, two core pins perpendicularly oriented with respect to one another may be inserted into a mold. Such a process increases manufacturing costs and time. Additionally, the abrupt, straight edged angle formed by multiple rigid pins may snag items threaded through the channel.
Embodiments of the present invention provide a system and method that efficiently form curved channels through molded components.
Certain embodiments of the present invention provide a system for forming a non-linear channel through a molded component. The system includes a forming device having a molding chamber, and a malleable core-out pin positioned within the molding chamber. The malleable core-out pin includes at least one curve or smooth sweeping bend. Plastic is injected into the molding chamber and flows around the malleable core-out pin to form the molded component. After the plastic solidifies and cools to form the molded component, the malleable core-out pin is removed to form the non-linear channel through the molded component.
The malleable core-out pin may be formed of soft steel, aluminum, gold or the like, depending on the desired malleability. The core-out pin may be formed of a rolled metal that is stretched to form a wire.
The malleable core-out pin re-shapes as it is removed from the molded component. That is, the core-out pin curves in conformity with the non-linear channel as it is extracted from the channel.
The molded component may include a base connected to a termination pocket and a port tube. The termination pocket may be offset from the port tube.
Certain embodiments of the present invention provide a molded component that includes a base, a termination pocket integrally formed with the base, a port tube extending from the base, and at least one curved core-out pin extending from the termination pocket to the port tube. The curved core-out pin is malleable and includes first and second ends. The first end extends out of the port tube and the second end extends into the termination pocket. The curved core-out pin is removed from the molded component to form a curved channel extending from the port tube to the termination pocket.
The at least one core-out pin may include two core-out pins configured to form channels for leads of a thermistor. The curved core-out pin(s) re-shape based on the shape of the curved channel(s) as they are removed from the molded component.
Certain embodiments of the present invention provide a method of forming a non-linear channel within a molded component. The method may include forming a malleable core-out pin, curving the malleable core-out pin to conform to a shape of a curved channel to be formed within the molded component, positioning the curved, malleable core-out pin within a molding chamber of a forming device, disposing or dispensing liquid plastic into the molding chamber around the curved, malleable core-out pin, allowing the liquid plastic to solidify and cool to form the molded component, removing the molded component from the molding chamber after the allowing step, and extracting the curved, malleable core-out pin from the molded component after the removing step to form the non-linear channel within the molded component.
The extracting step includes re-shaping the curved, malleable core-out pin during movement through the formed non-linear channel. That is, the core-out pin re-shapes itself as it is extracted. The method may also include threading an electrical lead into the non-linear channel after the extracting step.
The forming step may include rolling a malleable metal into a thin wire. Further, the curving step may include forming a rounded 900 bend in the core-out pin.
Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.
The core-out pins 10 are positioned within the molding chamber 22 such that the ends 12 protrude out of the molding chamber 22. As shown in
While the core-out pins 10 are shaped similar to that shown in
Hot liquid plastic is poured or injected into the molding chamber 22 after the core-out pins 10 are positioned therein. Once the plastic solidifies and cools, the resulting plastic molded component may be removed from the molding chamber 22.
As shown in
Once the core-out pins 10 are removed from the molded component 24, smooth, curved channels are formed through the molded component 24. That is, the solidified plastic ensures that smooth, curved channels remain within the molded component 24 after the core-out pins 10 are removed.
While the molded component 24 is shown having a base 26, pocket 28 and port tube 28, the molded component 24 may be various shapes and sizes depending upon a particular application. Additionally, the core-out pins 10 may be shaped and bent in various configurations before being inserted into the molding chamber 22 (shown in
Additionally, while the core-out pins 10 are grasped by the ends 14 and pulled in the direction of arrow A, the core-out pins 10 may be removed through another area. For example, the core-out pins 10 may be grasped by the ends 12 and pulled out of the molded component 24 in the direction of arrow B.
Next, at 54, the malleable core-out pin is bent and shaped to the shape of a channel to be formed through a molded component. As discussed above, for example, the core-out pin may be bent to have a smooth, curved bend such that one end of the core-out pin is perpendicularly-oriented with respect to the other end.
The core-out pin is then positioned within a molding chamber of a forming device at 56. The curved portion of the core-out pin is within the molding chamber. Next, plastic is injected, poured or otherwise flows into the molding chamber around the core-out pin at 58. The plastic surrounds the curved portion of the core-out pin, but not the ends of the core-out pin. Optionally, at least one end of the core-out pin may be surrounded by plastic. Such a situation may arise in which a channel having only one open end is desired, or in which portions (e.g., scraps or flashing) of the ensuing molded plastic component are later removed to expose the end(s) of the core-out pin.
Next, at 60, the molded component is removed from the molding chamber after the plastic solidifies and cools. Finally, at 62, the curved core-out pin is removed from the molded component. For instance, an end of the core-out pin may be grasped and pulled. Thus, the core-out pin is removed from the molded component and a smooth curved channel is formed within the molded component. Once the core-out pin is removed, it may be discarded and ultimately recycled.
Thus, embodiments of the present invention provide an apparatus and method for forming curved channels within molded components. The malleable core-out pins described above provide an efficient and easy way to form the channels. A single malleable core-out pin may form a curved channel. Moreover, because the core-out pin is malleable, it is safely removed from the molded component without damaging the resulting formed channel.
Embodiments of the present invention provide a core-out apparatus that is configured to form holes within a molded part that are connected together by a non-linear path. For example, embodiments of the present invention allow a termination pocket to be located somewhere other than directly in line with a port tube. The core-out apparatus shown and described allows the termination pocket to be located away from the port tube of a molded housing. By locating the termination pocket away from a computer chip or substrate pocket, lead wires may be attached without concern for damaging delicate wire bond surfaces of the chip or substrate pocket.
While various spatial terms, such as upper, lower, mid, lateral, horizontal, vertical, and the like may used to describe portions of the embodiments discussed above, it is understood that such terms are merely used with respect to the orientations shown in the drawings. The orientations may be inverted, rotated, or otherwise changed, such that an upper portion is a lower portion, and vice versa, horizontal becomes vertical, and the like.
Variations and modifications of the foregoing are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.
Various features of the invention are set forth in the following claims.
This application relates to and claims priority benefits from U.S. Provisional Patent Application No. 60/925,347 entitled “Core-Out Apparatus and Method,” filed Apr. 19, 2007, which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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60925347 | Apr 2007 | US |