Abstract:
A method is provided for molding an integral joint including a stationary member and an enclosure rotatable about the stationary member. The method utilizes a joint formation assembly defining an inner cavity, a first passageway connected to the inner cavity, an outer cavity surrounding the inner cavity, and a second passageway connected to the outer cavity. The method includes the steps of: introducing moldable material into the inner cavity from the first passageway to form the stationary member; introducing moldable material into the outer cavity from the second passageway to form the enclosure; and divorcing the inner cavity from the outer cavity for separately and independently forming the enclosure around the stationary member to allow rotatable movement of the enclosure about the stationary member.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application of U.S. patent application Ser. No. 12/305,096, which is a national phase application and claims the benefit, under 35 U.S.C. §371, of PCT/CA2007/001113, filed on Dec. 16, 2008, which in turn claims the priority of U.S. Provisional Application No. 60/815,524, filed on Jun. 20, 2006. All applications are incorporated herein by reference in their entireties. 
    
    
     FIELD OF THE INVENTION 
     The invention relates to a method and system of molding an integral joint. More particularly, the invention relates to a method of molding an integral joint including an enclosure rotatable about a stationary member. 
     DESCRIPTION OF RELATED ART 
     Molded articles are currently utilized in a wide variety of industries. Many of these molded articles include a joint or similar structure for connecting a first part to a second part. Typically, these joints have been formed with two distinct parts. First, a fixed member is molded into place. Then, a second molded member is secured to the fixed member. This two part process requires the use of fasteners or adhesives as well as secondary molding and installation operations. 
     SUMMARY OF THE INVENTION 
     According to one aspect of the invention, a method is provided for molding an integral joint including a stationary member and an enclosure rotatable about the stationary member. The method utilizes a joint formation assembly including an inner cavity, a first passageway connected to the inner cavity, an outer cavity surrounding the inner cavity, and a second passageway connected to the outer cavity. The method includes the steps of: introducing moldable material into the inner cavity from the first passageway to form the stationary member; introducing moldable material into the outer cavity from the second passageway to form the enclosure; and divorcing the inner cavity from the outer cavity for separately and independently forming the enclosure around the stationary member to allow rotatable movement of the enclosure about the stationary member. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
         FIG. 1  is a perspective view of a molded, integral joint for connecting first and second parts; 
         FIG. 2  is a another perspective view of the molded, integral joint connecting first and second parts; 
         FIG. 3  is a perspective view, partially cut away, of a stationary member of the integral joint; 
         FIG. 4  is an exploded, perspective view of a joint formation assembly for molding the integral joint; 
         FIG. 5  is an exploded, perspective view of the joint formation assembly; 
         FIG. 6  is a perspective view of the joint formation assembly in a ready position; 
         FIG. 7  is a perspective view of the joint formation assembly in the ready position; and 
         FIG. 8  is a top view of the integral joint. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIGS. 1 through 3 , a molded, integral joint, generally shown at  10 , connects first  12  and second  14  parts such that the second part  14  is rotatable relative to the first part  12 . The integral joint  10  may be formed by injection molding or injection-compression molding. In the present embodiment, the first part  12  is a semi-structural panel for a motor vehicle and the second part  14  is a vehicle door handle assembly. It is, however, appreciated that the first  12  and second  14  parts may be any of numerous structures for use in any of a variety of industries. 
     The integral joint  10  includes a stationary member  16  extending between opposing ends  18 ,  20 . A first tab  22  extends between one end  18  of the stationary member  16  and the first part  12 . A second tab  24  is spaced apart from the first tab  22  and extends between the opposing end  20  of the stationary member  16  and the first part  12 . Thus, the first  22  and second  24  tabs connect the stationary member  16  to the first part  12 . The first  22  and second  24  tabs are offset from one another along the stationary member  16 . It is appreciated that the shape of the first  22  and second  24  tabs may vary. 
     A rotatable member or enclosure  28  extends out from one end of the second part  14 . The rotatable member  28  surrounds the stationary member  16  and is free to rotate relative thereto. More specifically, the rotatable member  28  is not secured or attached to the stationary member  16  or to the first  22  and second  24  tabs. The rotatable member  28  is maintained along the stationary member  16  by the first  22  and second  24  tabs. 
     The particular structure, configuration, and size of the stationary  16  and rotatable  28  members may vary. In accordance with these variations, one may vary a space  29  (shown in  FIG. 8 ) between the stationary  16  and rotatable  28  members to increase or decrease the ability of the rotatable member  28  to rotate about the stationary member  16 . 
     A method of molding the integral joint  10  is now described with reference to  FIGS. 4 through 8 . The method of molding the integral joint  10  utilizes a joint formation assembly, generally shown at  30 , including a plurality of slides  32 ,  34 ,  36 ,  38 . In the present embodiment, the plurality of slides includes first  32  and second  34  central slides and first  36  and second  38  end slides. When all of the slides  32 ,  34 ,  36 ,  38  are moved into a ready position, as shown in  FIGS. 6 and 7 , moldable material is injected into the joint formation assembly  30  to form the integral joint  10 . 
     Referring now to  FIGS. 4 and 5 , the first central slide  32  includes an inboard surface  40  defining an outer cavity half  42 . The second central slide  34  includes an inboard surface  44  defining an outer cavity half  46 . In the present embodiment, each of the outer cavity halves  42 ,  46  has a semi-circular shape. The second central slide  34  also includes a top surface  48  defining a passageway  50 . The passageway  50  is fluidly connected to the outer cavity half  46 . 
     When the joint formation assembly  30  is in the ready position, as shown in  FIGS. 6 and 7 , the first  32  and second  34  central slides are moved against one another so that the inboard surfaces  40 ,  44  abut one another. At this time, the outer cavity halves  42 ,  46  are aligned with one another to form a continuous outer cavity  52 , as shown in  FIG. 6 . Moldable material is introduced into the passageway  50  to fill the entire outer cavity  52  and eventually form the rotatable member or enclosure  28 . 
     Referring back to  FIGS. 4 and 5 , each of the first  32  and second  34  central slides also includes an inner cavity portion  54 ,  56  that is divorced from the respective outer cavity half  42 ,  46  by a separating wall  59 . Each inner cavity portion  54 ,  56  extends between opposing ends  60 ,  62 . 
     The first end slide  36  includes an inboard surface, generally indicated at  64 , extending between an upper end  66  and a lower end  68 . The inboard surface  64  defines an inner cavity portion  70  along the lower end  68 . The inner cavity portion  70  is continuous with the inner cavity portion  56  of the second central slide  34 . In addition, when the joint formation assembly  30  is in the ready position, the inner cavity portion  70  closes around the inner cavity portion  54  at the end  60  thereof. The inboard surface  64  further defines an end cavity  72  that is shaped to form the tab  22 . A passageway  74  is formed in the first end slide  36  for receiving moldable material that will eventually enter the inner cavity portions  54 ,  56  in order to form the stationary member  16 . 
     The inboard surface  64  of the first end slide  36  also includes end portions  76 ,  78  on either side of the inner cavity portion  70 . When the joint formation assembly  30  is in the ready position, as shown in  FIGS. 6 and 7 , the end portions  76 ,  78  abut the top surface  48  of the second central slide  34  to seal off the outer cavity half  46  and the passageway  50 . As a result, moldable material entering the outer cavity half  46  from the passageway  50  is prevented from entering the inner cavity half  70  and the end cavity  72 . Thus, the outer cavity half  46  is completely divorced from the inner cavity portions  56 ,  70 . 
     The second end slide  38  also includes an inboard surface  80  extending between an upper end  82  and a lower end  84 . The inboard surface  80  defines an inner cavity portion  86  along the upper end  82 . The inner cavity portion  86  is continuous with the inner cavity portion  54  of the first central slide  32 . Together, the inner cavity portions  54 ,  56 ,  70 ,  86  form an inner cavity  87 . When the joint formation assembly  30  is in the ready position, the inner cavity portion  86  closes around the inner cavity portion  56  at the end  60  thereof. The inboard surface  80  further defines an end cavity  88  that is shaped to form the tab  24 . 
     The inboard surface  80  of the second end slide  38  also includes end portions  90 ,  92  on either side of the inner cavity portion  86 . When the joint formation assembly  30  is in the ready position, as shown in  FIGS. 6 and 7 , the end portions  90 ,  92  abut a bottom surface  94  of the first central slide  32  to seal off the outer cavity half  42 . As a result, moldable material entering the outer cavity half  42  is prevented from entering the inner cavity portion  86  and the end cavity  88 . Thus, the outer cavity half  42  is completely divorced from the inner cavity portions  54 ,  86 . Because the outer cavity halves  46 ,  42  are divorced from the respective inner cavity portions  56 ,  70  and  54 ,  86 , moldable material entering the outer cavity  48  from the passageway  50  is separated from moldable material entering the inner cavity portions  54 ,  56 ,  70 ,  86  and the end cavities  72 ,  88  from the passageway  74 , which in turn allows the independent formation of the rotatable member  28  along the stationary member  16 . It is this independent formation of the rotatable member or enclosure  28  that allows for rotation thereof about the stationary member  16 . 
     It is contemplated that although a particular structure for the plurality of slides  32 ,  34 ,  36 ,  38  has been shown and described for forming the integral joint  10 , the shape, size, configuration, and number of slides may vary depending upon the specific stationary and rotatable members to be molded. 
     In operation, the molding of the integral joint  10  begins with the movement of the joint formation assembly  30  into the ready position, shown in  FIGS. 6 and 7 . Moldable material is introduced into the first end slide  36  via the passageway  74 . The moldable material fills the end cavities  72 ,  88  and the inner cavity portions  54 ,  56 ,  70 ,  86 , which together form the inner cavity  87 . The moldable material in the inner cavity  87  and the end cavities  72 ,  88  forms the stationary member  16  and the tabs  22 ,  24 , respectively. Moldable material is also introduced into the second central slide  34  via the passageway  50 . The moldable material fills the outer cavity  52  to form the rotatable member  28 . It is appreciated that different moldable materials may be utilized to form the stationary member  16  and the rotatable member  28 . The separating wall  59  and the end portions  76 ,  78 ,  90 ,  92  prevent the moldable material in the outer cavity  52  from entering the inner cavity  87 . Thus, the rotatable member  28  independently and separately forms around the stationary member  16 , which allows rotation of the rotatable member  28  about the stationary member  16 . The end result is a permanent and flexible connection between the first part  12  and the second part  14 . 
     The particular order in which the rotatable member or enclosure  28  and the stationary structure  16  are molded may vary. More specifically, the molding of the rotatable member or enclosure  28  and the stationary member  16  can occur either simultaneously or sequentially. 
     The invention has been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the invention may be practiced other than as specifically described.