PATENT DOCUMENT

Publication Number: US-9475222-B2
Application Number: US-201213587504-A
Country: US
Kind Code: B2

Title: Method for forming injection-molded receptacle connector

Abstract:
A method of forming a part includes uni-directionally injecting a mold with material to form a molded part, removing the molded part from the mold, and forming at least one cavity in the molded part, the at least one cavity being defined by a machining process separate from a molding process.

Claims:
What is claimed is: 
     
       1. A method of forming a receptacle connector, comprising:
 uni-directionally injecting a mold with material to form a molded part, wherein a primary flow direction of the material during the injecting is substantially parallel to a top surface and a bottom surface of the molded part, and substantially orthogonal to a front surface and a back surface of the molded part; 
 removing the molded part from the mold; 
 forming a cavity in the molded part by removing a central region of the molded part so as to define an inner surface, wherein the removing forms a front opening within the front surface and a back opening within the back surface, wherein a width of the front opening, as defined in a first direction parallel to the front surface, is greater than a distance in the first direction between the inner surface and the top surface, and greater than a distance in the first direction between the inner surface and the bottom surface; and 
 populating the cavity with electrical contacts such that the receptacle connector can electrically connect with a corresponding plug via the front opening or the back opening. 
 
     
     
       2. The method of  claim 1 , wherein the molded part includes at least one protrusion that is configured to engage with a fastener. 
     
     
       3. The method of  claim 1 , further comprising preparing the mold for the uni-directional injecting by performing at least one of:
 cleaning the mold; 
 surface treatment of mold surfaces of the mold; and 
 assembly of the mold. 
 
     
     
       4. The method of  claim 1 , wherein the material includes fibers such that the fibers are oriented substantially parallel to the top surface and the bottom surface and substantially orthogonal to the front surface and the back surface. 
     
     
       5. The method of  claim 1 , wherein the electrical contacts are configured to severably connect with the corresponding plug. 
     
     
       6. The method of  claim 1 , wherein the molded part is a seamless part. 
     
     
       7. A method of forming a receptacle connector, comprising:
 forming a molded part by injecting a plastic material through a mold cavity in a primary direction toward a central region of the molded part, the primary direction during the injecting causing fibers within the plastic material to be oriented generally parallel to a top surface and a bottom surface of the molded part, and generally orthogonal to a front surface and back surface of the molded part; 
 removing the molded part from the mold cavity; 
 forming a cavity in the molded part by removing the central region of the molded part so as to define an inner surface, wherein the removing forms a front opening within the front surface and a back opening within the back surface, wherein a width of the front opening, as defined in a first direction parallel to the front surface, is greater than a distance in the first direction between the inner surface and the top surface, and greater than a distance in the first direction between the inner surface and the bottom surface; and 
 assembling an electrical connector within the cavity such that the receptacle connector can be electrically coupled with a corresponding plug via the front opening or the back opening. 
 
     
     
       8. The method of  claim 7 , further comprising preparing the mold cavity to receive the plastic material, wherein preparing the mold cavity comprises at least one of:
 cleaning the mold cavity; and 
 surface treatment of mold surfaces of the mold cavity. 
 
     
     
       9. The method of  claim 7 , wherein the orientation of the fibers is related to a directional stiffness of the receptacle connector. 
     
     
       10. The method of  claim 9 , wherein the electrical connector is configured to severably connect with the corresponding plug. 
     
     
       11. The method of  claim 7 , wherein the molded part is a seamless part. 
     
     
       12. The method of  claim 7 , wherein injecting the plastic material through the mold cavity comprises:
 uni-directionally injecting the plastic material through a single gate region. 
 
     
     
       13. The method of  claim 12 , wherein the single gate region is arranged on the front surface or the back surface. 
     
     
       14. The method of  claim 7 , wherein the plastic material is injected through a single gate region. 
     
     
       15. The method of  claim 7 , wherein removing the molded part is facilitated by compressed air.

Description:
FIELD OF THE DESCRIBED EMBODIMENTS 
     The described embodiments relate generally to injection molded parts, and more particularly, to uni-directionally injection molded parts. 
     BACKGROUND 
     Conventionally, injection molding processes employ a mold with two or more gate regions arranged to receive molten material for molding into a part. Molten material is injected into the two or more gate regions, flowed through a molding cavity, and cooled to form the part. The molten material, prior to cooling, meets at an interface between two or more flow directions and forms a knit line, or weld line. The knit line causes locally weak areas prone to breakage or failure of a molded part. 
     For example, as illustrated in  FIG. 1 , a conventionally molded part  100  includes a knit line  101  extended throughout the entire part  100  formed from two flow fronts flowing in opposite directions  102  and  103  through gate regions  121  and  131 , respectively. The knit line  101  may cause total failure of the part  100  if, for example, force is applied within cavity  104 . 
     Therefore, what is needed is an enhanced injection molded process by which knit line weakness can be reduced or eliminated entirely. 
     SUMMARY OF THE DESCRIBED EMBODIMENTS 
     This paper describes various embodiments that relate to injection molding of parts. 
     According to an embodiment of the invention, a method of forming a part includes uni-directionally injecting a mold with material to form a molded part, removing the molded part from the mold, and forming at least one cavity in the molded part, the at least one cavity being defined by a machining process separate from a molding process. 
     According to an additional embodiment of the invention, a method of forming a part includes preparing a mold cavity to receive material, flowing material through the mold cavity in a single primary direction to form a molded part, removing the molded part from the mold cavity, and forming at least one cavity in the molded part, the at least one cavity being defined by a machining process. 
     According to an additional embodiment of the invention, a seamless part includes a main body formed through a molding process and at least one cavity arranged in the main body defined by a machining process. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The described embodiments and the advantages thereof may best be understood by reference to the following description taken in conjunction with the accompanying drawings. 
         FIG. 1  is a perspective view of a conventionally injection molded part. 
         FIG. 2A  is a perspective view of a uni-directionally injection molded part, according to an embodiment of the invention. 
         FIG. 2B  is an elevation view of the uni-directionally injection molded part of  FIG. 2A . 
         FIG. 3  is a method of forming a part, according to an embodiment of the invention. 
         FIG. 4  is a perspective view of a uni-directionally injection molded part, according to an embodiment of the invention. 
         FIG. 5  is a perspective view of a uni-directionally injection molded part, according to an embodiment of the invention. 
         FIG. 6  is a perspective view of a uni-directionally injection molded part, according to an embodiment of the invention. 
         FIG. 7  is a perspective view of a uni-directionally injection molded part, according to an embodiment of the invention. 
         FIG. 8A  is an elevation view of a mold for forming a part, according to an embodiment of the invention. 
         FIG. 8B  is a side view of the mold of  FIG. 8A . 
         FIG. 9A  is an elevation view of a mold for forming a part, according to an embodiment of the invention. 
         FIG. 9B  is a side view of the mold of  FIG. 9A . 
     
    
    
     DETAILED DESCRIPTION OF SELECTED EMBODIMENTS 
     Representative applications of methods and apparatus according to the present application are described in this section. These examples are being provided solely to add context and aid in the understanding of the described embodiments. It will thus be apparent to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the described embodiments. Other applications are possible, such that the following examples should not be taken as limiting. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting; such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     Turning to  FIGS. 2A-2B , a perspective view and elevation view of a uni-directionally injection molded part are illustrated, according to an embodiment of the invention. The part  200  includes a main body  202  and fastener receiving protrusions  203  arranged on the main body  202 . The fastener receiving protrusions  203  may include through holes  201  arranged therethrough configured to receive a suitable fastener, such as, for example, a bolt, screw, clip, or other fastener. Although particularly illustrated as protrusions, it should be understood that the same may be varied in many ways, or omitted depending upon any desired implementation of the invention. Furthermore, the through holes  201  may be formed through injection molding, or may alternatively be formed through a machining process after molding of the part  200 . 
     The main body may have a cavity  204  formed therein exposed through at least one primary surface  205  of the part  200 . The cavity  204  may extend entirely through the main body  202  thereby forming a channel by which to support electrical connections in at least one embodiment. In other embodiments the main body  202  may include a through hole arranged to pass electrical connections from the internal cavity  204  to an opposing primary surface  206  opposite the at least one primary surface  205 . The cavity  204  may be a machined cavity defined by a machining process separate from a molding process. 
     The electrical connections which may be arranged in cavity  204  may include at least one electrode configured to severably connect to a complementary plug or device connection inserted into the cavity  204 . Therefore, the part  200  may be considered a receptacle configured to mate to a severable plug configured to engage with cavity  204 . As illustrated, the part  200  lacks any discernable knit line, is a seamless part, and is considerably more durable than part  100 . Therefore, if a plug is inserted and engaged with cavity  204 , the part  200  resists breakage due to insertion forces, is relatively stiff if the engaged plug is twisted, and may be longer-lasting than the part  100  during several re-connect cycles. 
     The lack of a knit line in part  200  is facilitated through a uni-directional injection molding process combined with a machining process by which opposing flows of material through a mold are eliminated or reduced as compared to convention processes. Hereinafter, methods of forming a part through injection molding are described in detail. 
       FIG. 3  is a method  300  of forming a part, according to an embodiment of the invention. The method  300  includes preparing a mold for a part at block  301 . Preparing the mold may include cleaning the mold, preparing mold surfaces (e.g., lubrication, sealing, polishing, etc), clamping one or more mold bodies together to form a mold cavity, preparing a mold cavity to receive material, and/or any other suitable preparatory processes. 
     The method  300  further includes uni-directionally injecting the prepared mold with material at block  303 . Uni-directionally injecting the prepared mold includes injecting material into the mold such that one primary flow front is formed, thereby mitigating risk of forming a knit line. Material is therefore flowed into a mold cavity in a single primary direction. The uni-directional injecting is facilitated by a single gate region arranged at one primary internal surface of the mold cavity. The primary internal surface of the mold cavity is a major surface defining an outer surface of an injection molded part, and is described more fully below with reference to  FIGS. 4-7 . 
     The material injected may include any suitable material in a liquid or partially liquid form, for example, plastic, thermoplastic, metal, amorphous metal, or any other desired material. The material may cool and harden, thereby forming a part. 
     The method  300  further includes removing the molded part from the mold or mold cavity at block  305 . For example, mold bodies may be separated to gain access to an interior of the mold (e.g., the mold cavity), and the part removed. Removal may be facilitated through application of compressed air, agitation of the mold, or by any suitable mechanism. 
     The method  300  further includes forming a cavity in the molded part at block  307 . For example, a cavity similar to cavity  204  may be defined by a machining process by which portions of material are removed. The machining process may include any suitable machining process, including computer-controlled machining processes and other automated processes. Lathes, drills, computer numerical control (CNC) machines, or other suitable tools may be used in this process. 
     Upon forming the cavity and any other preparatory steps, the part may be populated with electrical connections (e.g., if a receptacle) at block  309 , and/or may be used in assembly of a personal electronic device or other assembly process. Other preparatory steps may include removal of gate region remnants, formation of fastener receiving through holes similar to holes  201  (e.g., if not formed through injection molding), cleaning, polishing, inspection, or other suitable preparatory steps. 
     As described above, material is uni-directionally injected into a mold cavity to form the part  200 , which limits, reduces, or eliminates the possibility of multiple flow fronts forming a knit line, thereby resulting in a durable and seamless part. Hereinafter, several examples of gate regions on injection molded parts not yet machined are described with reference to  FIGS. 4-7   
       FIG. 4  is a perspective view of an injection molded part  400 , according to an embodiment of the invention. As illustrated, the part  400  lacks a knit line. Furthermore, the part  400  is formed through a single gate region  403  proximate a primary surface  401  of the part  400  using a single primary flow direction  402 . The primary flow direction  402  is the overall flow direction of injected material which formed the part  400 . The primary flow direction  402  may be substantially orthogonal to the primary surface  401 , or may be angled therefrom. The gate region  403  may remain attached to the part  400  after removal from a mold (e.g., as a remnant), and may be removed prior to or during machining processes. Generally, fiber orientation of cooled material (e.g., if using molten plastic as an injection material) will be substantially parallel to the primary flow direction  402 , and thus differing rigidity and stiffness characteristics may be achieved through altering the flow direction to be substantially orthogonal to a different surface than that illustrated. As such, any primary surface of a part may be used in choosing a primary flow direction, with several examples presented below. 
       FIG. 5  is a perspective view of an injection molded part, according to an embodiment of the invention. As illustrated, the part  500  lacks a knit line. Furthermore, the part  500  is formed through a single gate region  503  proximate a primary surface  501  of the part  500  using a single primary flow direction  502 . The primary flow direction  502  is the overall flow direction of injected material which formed the part  500 , and differs from direction  402 . The primary flow direction  502  may be substantially orthogonal to the primary surface  501 , or may be angled therefrom. The gate region  503  may remain attached to the part  500  after removal from a mold (e.g., as a remnant), and may be removed prior to or during machining processes. Generally, fiber orientation of the part  500  will be substantially orthogonal to fiber direction of the part  400  (e.g., if using molten plastic as an injection material). This may afford differing stiffness and rigidity characteristics, and may prove useful in deciding primary flow directions for parts depending upon cavity orientation or predicted internal stresses for a final part. Flow directions may also be chosen opposite to directions  402  and  502 , as illustrated in  FIGS. 6 and 7 . 
       FIG. 6  is a perspective view of an injection molded part, according to an embodiment of the invention. As illustrated, the part  600  lacks a knit line. Furthermore, the part  600  is formed through a single gate region  603  proximate a primary surface  601  of the part  600  using a single primary flow direction  602 . The primary flow direction  602  is the overall flow direction of injected material which formed the part  600 , and is opposite direction  502 . The primary flow direction  602  may be substantially orthogonal to the primary surface  601 , or may be angled therefrom. The gate region  603  may remain attached to the part  600  after removal from a mold (e.g., as a remnant), and may be removed prior to or during machining processes. 
       FIG. 7  is a perspective view of an injection molded part, according to an embodiment of the invention. As illustrated, the part  700  lacks a knit line. Furthermore, the part  700  is formed through a single gate region  703  proximate a primary surface  701  of the part  700  using a single primary flow direction  702 . The primary flow direction  702  is the overall flow direction of injected material which formed the part  700 , and is opposite direction  402 . The primary flow direction  702  may be substantially orthogonal to the primary surface  701 , or may be angled therefrom. The gate region  703  may remain attached to the part  700  after removal from a mold (e.g., as a remnant), and may be removed prior to or during machining processes. 
     As described above, multiple primary flow directions may be chosen according to any desired implementation of the present invention. Differing flow directions from those illustrated are also possible, however, illustration and description of every possible uni-directional flow pattern for all possible injection molded parts is beyond the scope of this disclosure. All equivalents acts or structures modified from the illustrated forms should be considered to be within the scope of this disclosure. 
     Hereinafter, several example mold configurations according to the teachings provided herein are described with reference to  FIGS. 8-9 . 
       FIGS. 8A-8B  include an elevation view and a side view of a mold  800  for forming a part similar to parts  400  and  700 , according to an embodiment of the invention. As shown, the mold  800  may include a first mold portion  801  and a second mold portion  802  defining an internal mold cavity  803 . The mold  800  may include a gate region  804  configured to receive and uni-directionally inject material into the mold cavity  803 . 
       FIGS. 9A-9B  include an elevation view and a side view of an alternate mold  900  for forming a part similar to parts  500  and  600 , according to an embodiment of the invention. 
     As shown, the mold  900  may include a first mold portion  901  and a second mold portion  902  defining an internal mold cavity  903 . The mold  900  may include a gate region  904  configured to receive and uni-directionally inject material into the mold cavity  903 . 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software to control injection molding and fabrication processes as described herein. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling manufacturing operations or as computer readable code on a computer readable medium for controlling a manufacturing line. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, and optical data storage devices. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20120816
Publication Date: 20161025
Grant Date: 20161025
Priority Date: 20120816
Inventors: JOL ERIC S.
MALEK SHAYAN
JONES WARREN Z.
Assignee: APPLE INC
CPC Classifications: [{"code": "B29C2045/0058", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/0046", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/0025", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R43/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2045/0058", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/0025", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C45/0046", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/18", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 50100338