Patent Publication Number: US-2022234264-A1

Title: Injection molded component and method of injection molding

Description:
This application in a continuation of U.S. application Ser. No. 16/675,542 filed Nov. 6, 2019, which is a divisional of U.S. application Ser. No. 15/899,085 filed Feb. 19, 2018, which claims priority to U.S. Provisional Application No. 62/472,816, which was filed on Mar. 17, 2017. 
    
    
     BACKGROUND 
     The disclosure relates to injection molded components. More particularly, the disclosure relates to injection molded components, such as pallets or receptacles, having at least one sensor associated with the injection molded component. 
     When packing or transporting goods on pallets or in receptacles, it is beneficial to the user to quickly and easily identify the goods stored on the pallet or in the receptacle, where the goods are being shipped, and/or the origin of the goods in addition to other information of the injection molded component. A number of approaches have been used to provide information to the user through the use of an indicator associated with the injection molded component. However, there is a need to improve the manufacturability of the injection molded components and the operability of indicators associated with the injection molded components. 
     SUMMARY 
     In one exemplary embodiment, an injection molded component includes a wall that has an inner wall surface and an outer wall surface. A sensor is molded into one of the inner wall surface and the outer wall surface. A channel is at least partially surrounding the sensor. 
     In another exemplary embodiment, a mold assembly includes a first mold wall that includes an inner surface. A wall extends from the inner surface to define a suction surface. At least one vacuum line is in fluid communication with the suction surface. A second mold wall opposes the first mold wall and includes at least one extendable pin. 
     In another exemplary embodiment, a mold assembly includes a first mold wall that includes an inner surface. A portion of the inner surface defines a recessed surface. A first plurality of ribs extends across the recessed surface and includes a sensor contact surface that extends in a plane parallel to the recessed surface. 
     In another exemplary embodiment, a method of forming an injection molded component comprising the step of locating a sensor against a first surface of a mold. An edge of the sensor is surrounded by a wall that extends from the first surface of the mold. An injectable material is injected into the mold such that the injectable material travels over an inner surface of the sensor. 
     These and other features of the disclosed examples can be understood from the following description and the accompanying drawings, which can be briefly described as follows. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an example injection molded component, such as a pallet, according to a non-limiting example of this disclosure. 
         FIG. 2  illustrates an enlarged view of a portion of the pallet of  FIG. 1  including an example tag. 
         FIG. 3  is an enlarged cross-sectional view taken along line  3 - 3  of  FIG. 2 . 
         FIG. 4  is an enlarged cross-sectional view of the example tag taken along line  4 - 4  of  FIG. 2 . 
         FIG. 5  is an enlarged cross-sectional view of another example tag. 
         FIG. 6  is an enlarged cross-sectional view of yet another example tag. 
         FIG. 7  is a cross-sectional view of a mold illustrating flow patterns. 
         FIG. 8  is a perspective view of a portion of the mold shown in  FIG. 7 . 
         FIG. 9  is a perspective view of an example suction surface of the mold shown in  FIG. 7 . 
         FIG. 10  illustrates a portion of an automation system for manipulating the example tag of  FIG. 2 . 
         FIG. 11  illustrates another portion of the automation system of  FIG. 10 . 
         FIG. 12  is a perspective view of another example suction surface of the mold. 
         FIG. 13  is a perspective view of yet another example suction surface of the mold. 
         FIG. 14  is a perspective view of a portion of the pallet of  FIG. 1  including the example tag of  FIG. 2  having a visual indicator. 
         FIG. 15  is a perspective view of a portion of another example mold. 
         FIG. 16  is a perspective view of the portion of the mold of  FIG. 15  with a sensor. 
         FIG. 17  is a perspective view of the sensor of  FIG. 16  molded into a portion of the pallet of  FIG. 1 . 
         FIG. 18  illustrates a cross-sectional view taken along line  18 - 18  of  FIG. 17 . 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a pallet  10  according to one non-limiting example of this disclosure. The pallet  10  includes a top deck  12  and a bottom deck  14 . The top deck  12  and the bottom deck  14  are molded from a plastic material such as polypropylene via an injection molding process, but of course may be formed of various polymeric materials and processes to achieve the desired characteristics. 
     The top deck  12  includes an upper surface  16  for supporting goods thereon. The top deck  12  mates with the bottom deck  14  at a mating line  18 . The bottom deck  14  includes multiple columns  20  that extend downward. The columns  20  located along a perimeter of the pallet  10  include a wall having an outer surface  22  that is generally flat. One or more of the outer surfaces  22  include a RFID tag  30  molded into the column  20 . Although the RFID tag  30  is shown in one of the columns  20 , the RFID tag  30  could also be located in the upper surface  16  or another suitable location on the pallet  10 . Moreover, multiple RFID tags  30  could be incorporated into the pallet  10 . Additionally, the RFID tag  30  could be used in another injection molded product, such as a crate or another type of receptacle. Moreover, other sensors, such as UHF, NFC, GPS, Bluetooth, and temperature sensors, could be used in place of or in addition to the RFID components in the RFID tag  30 . 
       FIG. 2  illustrates an enlarged view of the RFID tag  30  in the outer surface  22  of the column  20 . The column The RFID tag  30  includes an antenna  32  capable of communicating with a remote device  31 , such as a RFID tag reader, through radio wave communication. The RFID tag  30  transmits information about the pallet  10 , the goods stored on the pallet  10 , or the origin/destination of the goods stored on the pallet  10  to the remote device  31 . In the illustrated non-limiting example, the antenna  32  follows an elongated serpentine pattern such that the RFID tag  30  has an elongated rectangular shape in the outer surface  22  of the column  20 . 
     The RFID tag  30  includes an outer construction  34  that is flush or recessed with respect to the outer surface  22  of the column  20 . The outer construction  34  provides protection for the antenna  32 .  FIG. 3  is a cross-sectional view through the outer surface  22  and the outer construction  34  but not the antenna  32  along line  3 - 3  of  FIG. 2 . The antenna  32  is located between the outer construction  34  and the column  20 . The outer construction  34  can be the same material as the injection molded portion of the pallet  10  or a dissimilar material. The outer construction  34  can also match the color of the column  20  or be of a contrasting color to the column  20 . The outer construction  34  is also surrounded by a channel  36  that separates the outer construction  34  from the outer surface  22  of the column  20 . 
       FIG. 4  illustrates a cross-sectional view of the RFID tag  30  along line  4 - 4  of  FIG. 2 . In the illustrated non-limiting example, the RFID tag  30  includes the outer construction  34  having a first construction surface  33  and a second construction surface  35  on an opposite side of the outer construction  34  from the first construction surface  33 . The first construction surface  33  of the outer construction  34  faces the same direction as the outer surface  22  of the column  20 . 
     The antenna  32  is printed directly onto the second construction surface  35  of the outer construction  34  such that the antenna  32  is spaced from the outer surface  22  of the column  20  by the thickness of the outer construction  34 . The antenna  32  and a portion of the second construction surface  35  not covered by the antenna  32  would face into the column  20  of the pallet  10  and be located adjacent and bond to the injection molded material of the pallet  10 . In the illustrated non-limiting example, a thickness dimension of the outer construction  34  is greater than a thickness dimension of the antenna  32  and the antenna  32  only covers a portion of the second construction surface  35 . 
       FIG. 5  illustrates a cross-sectional view of another example RFID tag  30 A. The RFID tag  30 A is similar to the RFID tag  30  except where noted below or shown in the Figures. The RFID tag  30 A includes the outer construction  34 , a first layer of adhesive  40 , the antenna  32 , and an inlay  38 . 
     Instead of the antenna  32  being printed directed onto the outer construction  34  as with the RFID tag  30  shown in  FIG. 4 , the antenna  32  in the RFID tag  30 A is attached to the second construction surface  35  of the outer construction  34  with the first layer of adhesive  40  located between the antenna  32  and the outer construction  34 . 
     Because the antenna  32  is not printed directly onto the outer construction  34  in the RFID tag  30 A, the inlay  38  is used to provide support for the antenna  32 . The antenna  32  is attached to a first inlay surface  37  on the inlay  38 . The inlay  38  also includes a second inlay surface  39  located on an opposite side of the inlay  38  from the first inlay surface  37  and the antenna  32 . The second inlay surface  39  faces into the column  20  of the pallet  10  and would be located adjacent and bond to the injection molded material of the pallet  10  along with a portion of the second construction surface  35  of the outer construction  34 . 
     In the illustrated non-limiting example, a thickness dimension of the outer construction  34  is greater than a thickness dimension of the antenna  32  and a thickness dimension of the inlay  38 . The thickness dimension of the inlay  38  is less than a thickness dimension of the outer construction  34  and greater than a thickness dimension of the antenna  32 . 
     The inlay  38  can be made of the same material as the outer construction  34  or of a dissimilar material from the outer construction  34 . When the inlay  38  is made of a similar material as the outer construction  34 , the inlay  38  will act as a heat shield during molding of the pallet  10  and reduce the amount of blistering that appears on the first construction surface  33  that can result from molding. 
       FIG. 6  illustrates a cross-sectional view of yet another non-limiting example RFID tag  30 B. The RFID tag  30 B is similar to the RFID tags  30 ,  30 A except where noted below or shown in the Figures. The RFID tag  30 B includes the outer construction  34 , the first layer of adhesive  40 , the antenna  32 , the inlay  38 , a second layer of adhesive  44 , and an inner construction  42 . 
     Instead of the inner most layer of the RFID tag  30 B being the inlay  38  as shown with the RFID tag  30 A in  FIG. 5 , the RFID tag  30 B includes the second layer of adhesive  44  and the inner construction  42  located inward from the second inlay surface  39 . The inner construction  42  includes a first inner construction surface  41  and a second inner construction surface  43  located on an opposite side of the inner construction  42  from the first inner construction surface  41 . The second layer of adhesive  44  contacts the second inlay surface  39  and the first inner construction surface  41  to fix the inlay  38  relative to the inner construction  42 . 
     In the non-limiting illustrated example, dimensions of the first and second inner construction surfaces  41 ,  43  are equal to or greater than dimensions of the first and second inlay surfaces  37 ,  39 . Additionally, the dimensions of the first and second inner construction surfaces  41 ,  43  are less than dimensions of the first and second construction surfaces  33 ,  35 . As described above in relation to the inlay  38  in the RFID tag  30 A, the inner construction  42  will also further act as a heat shield during molding of the pallet  10  and reduce the amount of blistering that appears on the first construction surface  33  that can result from molding. 
     In the illustrated non-limiting example, a thickness dimension of the outer construction  34  is greater than a thickness dimension of the antenna  32  and a thickness dimension of the inlay  38 . The thickness dimension of the inlay  38  is less than a thickness dimension of the outer construction  34  and greater than a thickness dimension of the antenna  32 . A thickness dimension of the inner construction  42  is greater than the thickness dimension of the inlay  38  and less than or equal to the thickness dimension of the outer construction  34 . 
     In order to ensure that the RFID tag  30  remains in a desired orientation while material is injected into the mold to form the pallet  10  or any other injection molded product, a unique mold confirmation is utilized.  FIG. 7  illustrates a cross-sectional view of the mold and RFID tag  30 . The unique molding configuration incorporates a combination of a wall or dam  62  in a mold surface and vacuum lines  52  and/or pins  54  as shown in  FIGS. 7-9 . A heat source  57  can also be used to warm the RFID tag  30  to encourage bonding with the injected material. 
       FIG. 7  illustrates a cross-sectional view of a pallet mold through the RFID tag  30 . The mold includes an outer portion  56  and an inner portion  58 . The outer portion  56  includes an inner surface  60  that forms the outer surface  22  of the column  20 . The RFID tag  30  is also located adjacent the inner surface  60  of the outer portion  56  of the mold. 
     The inner surface  60  of the mold also includes the wall  62  that surrounds the RFID tag  30 . The height of the wall  62  is greater than a thickness of the entire RFID tag  30 . In the illustrated embodiment, the wall  62  surrounds a portion of the inner surface  60  to define a suction surface  64  dimensioned to be larger than the first construction surface  33  of the outer construction  34 , which is the portion of the RFID tag  30  that is in contact with the inner surface  60 . 
     The vacuum lines  52  are in fluid communication with the suction surface  64  to generate a suction force to hold the RFID tag  30  to the inner surface  60 . The pins  54  are extendable across the mold to engage an inner surface of the RFID tag  30  to further maintain the RFID tag  30  in place during the initial stages of the molding process. Although multiple suction lines  52  are shown in the illustrated non-limiting embodiment, only a single suction line could be used. The pins  54  are removed during the injection molding process to prevent the formation of passageways extending through the wall of the column  20  an inner side of the RFID tag  30 . 
     In one example, the suction surface  64  is larger than the outer construction  34  on RFID tag  30  to allow material injected into the mold to fill a space between a perimeter of the RFID tag  30  and the wall  62 . In another example, a perimeter of the outer construction  34  fits tightly against the wall  62  such that injected material will not reach the suction surface  64 . 
     The wall  62  protects to the RFID tag  30  during the injection molding process to prevent the RFID tag  30  from moving or shifting during the injection molding process. Arrows  66  indicate possible flow directions for the injected material entering the mold and passing over the RFID tag  30 . When the injected material travels over the wall  62 , the wall  62  prevents the injected material from moving the RFID tag  30  by disrupting the generally linear flow of the injected material and creating turbulent flow fields as indicated by arrows  68  adjacent the wall  62  and the RFID tag  30 . 
       FIGS. 8 and 9  illustrate a portion of the outer portion  56  and the inner portion  58  of the mold on opposite sides the RFID tag  30  that engage the RFID tag  30  with only the suction surface  64  shown on the inner surface  60 . The vacuum lines  52  are in fluid communication with the suction surface  64  to provide a negative pressure through a suction force from the external source  55  ( FIG. 5 ) to secure the first construction surface  33  of the outer construction  34  of the RFID tag  30  against the suction surface  64 . 
     The pins  54  retractably extend through the inner portion  58  of the mold to engage the inner surface of the RFID tag  30  to further secure the RFID tag  30  against the suction surface  64 . The pins  54  retract once a predetermined amount of material has been injected into the mold to prevent the formation of passageways through the columns  20  to the RFID tag  30 . Alternatively, the pins  54  are extended during the high speed injection phase and retract during the slow speed injection phase. 
       FIG. 10  illustrates a portion of an automation system  100  used for placing the RFID tag  30  against the suction surface  64  within the mold. The automation system  100  engages the RFID tag  30  with a suction device  102 . The suction device  102  includes a suction head  104  for directly contacting and manipulating the RFID tag  30  and a suction line  106  in fluid communication with a suction source  108 . The suction device  102  transports the RFID tag  30  past a static charger  110  having a static charging head  112 , which applies a static charge to the RFID tag  30  to assist in securing the RFID tag  30  against the suction surface  64  as discussed below. 
     The suction device  102  then places the RFID tag  30  against the suction surface  64  of the outer portion  56  of the mold. A leveling member  114  of the automation system  100  includes soft contacts  116  connected to an extendable arm  118 . The extendable arm  118  of the leveling member  114  extends past the suction device  102  to engage an inner surface of the RFID tag  30  that extends outward past the suction head  104 . Because a portion of the RFID tag  30  extends past the suction head  104  in the illustrated example, the RFID tag  30  could curl away from the suction surface  64  and extend into the injection flow. To prevent this from happening, the leveling member  114  engages the inner surface of the RFID tag  30  and presses the RFID tag  30  against the suction surface  64 . The static charge on the RFID tag  30  from the static charger  110  also prevents the RFID tag  30  from curling when placed against the suction surface  64 . 
       FIG. 12  illustrates the inner portion  58  and RFID tag  30  with another example outer portion  56 A. The outer portion  56 A is similar to the outer portion  56  except were described below or shown in the Figures. 
     Vacuum lines  52 A are in fluid communication with a vacuum channel  70 A in a suction surface  64 A to provide a negative pressure through a suction force from the external source  55  ( FIG. 7 ) to secure the first construction surface  33  of the outer construction  34  of the RFID tag  30  against the suction surface  64 A. In the illustrated non-limiting example, the vacuum channel  70 A is recessed into the suction surface  64 A and includes a rectangular shape corresponding to the shape of the RFID tag  30 . 
       FIG. 13  illustrates the inner portion  58  and RFID tag  30  with yet another example outer portion  56 B. The outer portion  56 B of the mold is similar to the outer portion  56  except were described below or shown in the Figures. 
     Vacuum lines  52 B are in fluid communication with a porous material  72 B in a suction surface  64 B to provide a negative pressure through a suction force from the external source  55  ( FIG. 7 ) to secure the first construction surface  33  of the outer construction  34  of the RFID tag  30  against the suction surface  64 A. Because the porous material  72 B covers a larger area of the suction surface  64 B, the RFID tag  30  can be secured with greater force. Additionally, the large surface area of the porous material  72 B allows the RFID tag  30  to be placed against the suction surface  64 B with less accuracy because the RFID tag  30  can establish a sufficient seal by overlapping with a smaller portion of the porous material  72 B. 
       FIG. 14  illustrates another example RFID tag  30 A similar to the RFID tag  30  except where described below or shown in the Figures. The outer construction  34 A includes an identifier  74 , such as a bar code and/or alpha numeric characters, to provide a visual indication regarding origin, destination, and/or contents stored on the pallet  10 . The identifier  74  can be formed into a surface of the outer construction  34 A or attached with a sticker. 
       FIG. 15  illustrates a further example outer portion  56 C that engages a sensor  63 C ( FIG. 16 ), such as RFID, UHF, NFC, GPS, Bluetooth, or temperature sensor. The sensor  63 C is covered in a thin wall of plastic to protect the electronics within. The outer portion  56 C does not rely on suction as described with the suction surfaces  64  described above. 
     The outer portion  56 C includes a recessed surface  65 C facing into a cavity defined by the mold. The recessed surface  65 C corresponds in shape to the sensor  63 C. A first plurality of side supporting ribs  69 C position the sensor  63 C a proper distance from the recessed surface  65 C to allow injected material to fill the space defined by the recessed surface  65 C and a side surface of the sensor  63 C. 
     A second plurality of ribs  71 C include ledges  73 C that position the sensor  63 C a proper distance from to an upper and lower edge of the recessed surface  65 C. Although the horizontal and vertical aligning function are performed separately by the first and second plurality of ribs  69 C and  71 C, respectively, the horizontal and vertical alignment function of these ribs  69 C and  71 C could be combined into a single rib. Additionally, the first and second plurality of ribs could be arranged in an alternating configuration or in groups of at least two similar ribs adjacent to each other. Moreover, the recessed surface  65 C and the first and second plurality of ribs  69 C and  71 C could be located in the inner portion  58  of the mold. 
     As shown in  FIGS. 17 and 18 , the sensor  63 C is at least partially suspended in the column  20  of the pallet  10 . The outer surface  22  of the pallet  10  also includes a plurality of slots  74  that correspond to the first and second plurality of ribs  69 C and  71 C. The sensor  63 C is visible through the slots  74 . 
     Although the different non-limiting embodiments are illustrated as having specific components, the embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments. 
     It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should also be understood that although a particular component arrangement is disclosed and illustrated in these exemplary embodiments, other arrangements could also benefit from the teachings of this disclosure. 
     The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claim should be studied to determine the true scope and content of this disclosure.