Patent ID: 7670524

Claim:
A method of forming an over-molded part, the method comprising: combining a first mold section and a second mold section to form a first mold cavity, the first mold section having a first molding surface and a retractable tool portion and the second mold section having a second molding surface wherein the first mold cavity is defined by the first molding surface and the second molding surface, the retractable tool portion having a retractable tool surface; injecting a first thermoplastic resin into a first mold cavity at a sufficient temperature and pressure to fill the first mold cavity and form a first molded part; separating the second mold section from the first mold section such that the first molded part remains in contact with the first molding surface; retracting the retractable tool portion at an angle with respect to a horizontal plane in a direction away from the first molding surface to expose one or more channels such that the angle at which the retractable tool portion is retracted is different than an angle between a tangent plane to the retractable tool surface and a horizontal plane, the one or more channels being defined by the first mold section and the first molded part, the one or more channels providing access to an isolated region; combining a third mold section with the first mold section to form a second mold cavity, the second mold cavity being defined by the first molded part, exposed surfaces of the first molding surface, and the third molding surface; and injecting a second thermoplastic resin through the exposed channels defined by the first mold section and the first molded part into the second mold cavity at a sufficient temperature and pressure to fill the second mold cavity and form the over-molded part, the over-molded part being the second molded part attached to the first molded part.