Patent ID: 8226390

Claim:
An insert molding device, comprising: an upper mold half having a first mating surface; a lower mold half having a second mating surface, the first and second mating surfaces configured to matingly couple to define a cavity therebetween, the cavity configured to receive an inserted workpiece therein, a portion of the cavity enlarged to provide a molding chamber surrounding a region of the inserted workpiece; at least one compressible material coupled to the second mating surface of the lower mold half; an injection gate having an outlet defined therein opening into the molding chamber, the injection gate configured to deliver molten plastic under pressure into the molding chamber for molding the molten plastic on the inserted workpiece; and wherein the upper mold half includes: an upper plunger; and at least one spring coupled between the upper plunger and the upper mold half, the at least one spring configured to bias the upper plunger against the inserted workpiece and the compressible material when the first and second mating surfaces are matingly coupled to form at least a first portion of a flash barrier along the molding chamber.