Patent ID: 6849219

Claim:
A method of moulding an article comprising the steps of: (a) bringing together a first die with a second die in a first relative position to form first and second moulds, the first mould being defined between a single male die core of the second die and a single female die cavity of the first die and the second mould being defined between a single male die core of the first die and a single female die cavity of the second die; (b) using a single injection device to deliver a first amount of molten material which is relayed to both of the first and second moulds respectively via first and second runner drops defined in the first die, to form first and second moulded parts; (c) separating the first die from the second die to remove the male die cores from the female die cavities whilst retaining the first and second moulded part in the female die cavities; (d) moving the second die relative to the first die to a second relative position in which the female die cavity of the first die aligns with the female die cavity of the second die; (e) bringing together the first and second dies in the second relative position to bring together facing surfaces of the first moulded part situated in the female die cavity of the first die and the second moulded part situated in the female die cavity of the second die, the female die cavities of the first and second dies together defining a third mould in which both previously moulded parts are located; (f) using the single injection device to deliver a second amount of molten material to the third mould via the first runner drop, which molten material surrounds a part at least of each previously moulded part and then solidifies to connect and joint together the two previously moulded parts to form a single moulded entity; (g) removing the single moulded entity from the separated first and second dies; and (h) moving the first and second dies back to the first relative position and bringing the fist and second dies together to commence a further cycle and form a second moulded entity.