Patent ID: 8119049
Filing Date: 2012-02-21
Classification: B29C

Abstract:
1. An injection molding process comprising: (a) positioning a retractable core within a mold cavity to hold two or more electrically conductive inserts in a desired position within the mold cavity, wherein the retractable core comprises a portion in the mold cavity that separates the two or more inserts in the mold cavity and prevents the two or more inserts from contacting each other during an injection of hot molten plastic into the mold cavity, wherein the retractable core is configured to restrict movement of a proximal portion of each of the two or more inserts in at least one horizontal direction and one vertical direction, further wherein the mold cavity is defined by a first mold plate and a second mold plate and the retractable core is a feature of the second mold plate; (b) while the two or more inserts are being held in the desired position by the retractable core, initiating the injection of hot molten plastic into the mold cavity through at least one gate located in close proximity to the retractable core, wherein the injected plastic: (i) substantially fills a first cavity space encompassing the gate and the proximal portion of each of the two or more inserts, and (ii) substantially fills a second cavity space encompassing a distal portion of each of the two or more inserts and located beyond the first cavity space in relation to the gate; (c) continuing the injection of hot molten plastic into the mold cavity, and at such time that the injected plastic in the second cavity space has cooled and hardened sufficiently to substantially secure the distal portion of each of the two or more inserts from movement and the injected plastic in the first cavity space is still sufficiently warm and molten to securely bond to newly injected hot molten plastic, retracting the retractable core from its position restricting the movement of a proximal portion of each of the two or more inserts, wherein retracting the retractable core creates an additional cavity space within the mold cavity between the retractable core and the two or more inserts; and (d) continuing the injection of hot molten plastic into the mold cavity until the mold cavity, including the additional cavity space, is filled.