Patent ID: 8894399

Claim:
An injection molding system for forming a plurality of molded parts, each molded part including a first portion and a second portion, the injection molding system comprising: a first tool for performing a first injection molding shot forming the first portion of each of the molded parts, the first tool comprising a plurality of first cavities for forming a plurality of the first portions and at least one gate that allows molten material to flow into the first cavities, wherein each of the plurality of the first portions are connected to a gate portion formed from the molten material within the at least one gate; and a second tool for performing a second injection molding shot forming the second portion on each of the plurality of the first portions of the molded parts transferred from the first tool, wherein the second tool has a plurality of second cavities for forming a plurality of the second portions of the plurality of parts, the second tool comprising: at least one punch configured to press on and remove the gate portion from each of the plurality of the first portions, and at least one channel arranged to accept the removed gate portion, the at least one channel having a cross-sectional shape in accordance with the gate portion preventing shifting of the gate portion during removal; wherein the plurality of first cavities and the at least one gate are configured such that the plurality of first portions are maintained a first distance apart from one another by the gate portion when the plurality of first portions and gate portion are transferred from the first injection molding tool to the second injection molding tool.