PATENT DOCUMENT

Publication Number: US-9694526-B2
Application Number: US-201314038176-A
Country: US
Kind Code: B2

Title: Injection mold with multi-axial core inserts

Abstract:
Systems and methods of providing a tooling system for forming a unitary housing are disclosed herein. One embodiment may utilize a plurality of injection cavity slides. The slides may form the interior cavity of the housing. Utilizing a plurality of injection cavity slides to form a single cavity insert may allow the slides to be remove from an opening in the housing which is smaller than the cavity of the housing. Removing the slides from housing allows for the formation of housing having a unitary structure.

Claims:
We claim: 
     
       1. A housing for electronic components, the housing comprising:
 a body having a major interior surface that defines an interior cavity and a major exterior surface comprising at least first and second intersecting surfaces; 
 a major aperture formed in the body and extending from the interior cavity through the major interior surface and major exterior surface, wherein the major aperture passes through a portion of the first surface and the second surface but not the entirety of the first surface and the second surface and wherein the interior cavity is dimensionally larger than the major aperture such that a largest cross-section of the interior cavity is larger than a largest cross-section of the major aperture; 
 a receiving lip formed around a perimeter of the major aperture; 
 a retention cap having first and second exterior cap surfaces that intersect at an elbow of the retention cap, wherein the retention cap is coupled to the receiving lip such that the first and second exterior cap surfaces are flush with the first and second surfaces of the body, respectively, and wherein the retention cap includes a protrusion that extends outward from the first exterior cap surface and a minor aperture that extends through the second exterior cap surface to the interior cavity; and 
 wherein the housing body is of a single, unitary construction formed of a rigid material of substantially uniform thickness that defines the entirety of the major exterior surface such that the major exterior surface does not include any seams. 
 
     
     
       2. The housing of  claim 1  wherein the body includes at least one interior surface feature configured to couple to electronic components. 
     
     
       3. The housing of  claim 1 , wherein the major aperture additionally passes through a portion of a third surface and a fourth surface. 
     
     
       4. The housing of  claim 3 , wherein the major aperture comprises a substantially L-shaped cross section. 
     
     
       5. The housing of  claim 3 , wherein the first surface is orthogonal to the second surface, the third surface and the forth surface; wherein the second surface is orthogonal to the third surface and the forth surface; wherein the third surface and the fourth surface are parallel to one another. 
     
     
       6. The housing of  claim 5 , wherein the first surface, the second surface, the third surface and the fourth surface are all contiguous and have no separate surfaces mechanically attached to form any of the first surface, the second surface, the third surface and the forth surface. 
     
     
       7. The electronic device housing set forth in  claim 1  wherein major exterior surface of the body includes first and second opposing faces each of which is shaped as a concave hexagon having all right angles with at least some rounded corners. 
     
     
       8. A housing, comprising:
 an injection-molded body defining an interior cavity therein, the injection molded body having a major exterior surface comprising at least first surface and second intersecting surfaces; and
 a major aperture passing through the injection-molded body and opening to the interior cavity; 
 
 a receiving lip formed around a perimeter of the major aperture; 
 a retention cap having first and second exterior cap surfaces that intersect at an elbow of the retention cap, wherein the retention cap is coupled to the receiving lip such that the first and second exterior cap surfaces are flush with the first and second surfaces of the body, respectively, and wherein the retention cap includes a protrusion that extends outward from the first exterior cap surface and a minor aperture that extends through the second exterior cap surface to the interior cavity; 
 wherein the interior cavity is dimensionally larger than the major aperture such that a largest cross-section of the interior cavity is larger than a largest cross-section of the aperture; and
 the injection-molded body is of a unitary construction that does not include any seams along the major exterior surface. 
 
 
     
     
       9. The housing of  claim 8 , wherein the injection-molded body lacks a seam. 
     
     
       10. The housing of  claim 8 , wherein:
 the injection-molded body defines at least a pair of sidewalls adjacent one another; and 
 the aperture passes through the at least a pair of sidewalls. 
 
     
     
       11. The electronic device housing set forth in  claim 8  wherein major exterior surface of the body includes first and second opposing faces each of which is shaped as a concave hexagon having all right angles with at least some rounded corners. 
     
     
       12. An electronic device housing comprising:
 a seamless body having a major exterior surface and a major interior surface that combine to define a plurality of walls which in turn define an interior volume, wherein the plurality of walls includes first and second opposing faces and a sidewall extending between the first and second opposing faces along a perimeter of the seamless body, the sidewall including first, second, third and fourth sidewall faces where the first and second sidewall faces meet at a first corner, the second and third sidewall faces meet at a second corner and the third and fourth sidewall faces meet at a third corner in a catercorner position to the first corner; 
 a major aperture formed at a corner of the seamless body catercorner to the second corner and opening to the interior volume, the major aperture formed between the first and second opposing faces and between the first and fourth sidewall segments, and the major aperture having a cross-sectional dimension between the first and fourth sidewall segments that is less than a cross-sectional dimension of the interior volume between the first and third corners; 
 a receiving lip formed around a perimeter of the major aperture; and 
 a retention cap having first and second exterior cap surfaces that intersect at an elbow of the retention cap, wherein the retention cap is coupled to the receiving lip such that the first and second exterior cap surfaces are flush with the first and fourth sidewall segments of the body, respectively. 
 
     
     
       13. The electronic device housing set forth in  claim 12  further comprising a first electronic module comprising a plurality of electronic components, the first electronic module having a length that is substantially equal to a interior dimension of the internal cavity, a width that is substantially equal to the cross-sectional dimension of the major aperture between the third and fourth sidewall segments, and rounded corners that enable the first electronic module to be inserted through the aperture into the internal cavity and then rotated into a final position. 
     
     
       14. The electronic device housing set forth in  claim 13  further comprising a second electronic module coupled to the first electronic component. 
     
     
       15. The electronic device housing set forth in  claim 12  wherein the first, second and third corners are each rounded. 
     
     
       16. The electronic device housing set forth in  claim 15  wherein each of the first and second opposing faces is shaped as a concave hexagon having all right angles. 
     
     
       17. The electronic device housing set forth in  claim 16  wherein the retention cap includes a protrusion that extends outward from the first exterior cap surface and a minor aperture that extends through the second exterior cap surface to the interior volume.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/799,065 filed 15 Mar. 2013 and entitled “Injection Mold with Multi-Axial Core Inserts,” which is incorporated by reference herein in its entirety. 
    
    
     TECHNICAL FIELD 
     This disclosure relates generally to an injection mold for forming a unitary housing, and in particular to methods of assembling and disassembling the same, suitable for injection molding of a housing of unitary construction, the housing having internal surface features suitable for receiving electronic components. 
     BACKGROUND 
     Housings of various forms are used to contain and protect electronic components internal to the housings. Housings may be made lightweight. Reducing the material weight of a housing often reduces strength and durability which increases the likelihood of device failure if dropped on a hard surface. Alternately, selecting lighter materials of equivalent strength may be cost prohibitive to electronic device manufacturers. Furthermore, electronic device housings are often composed of multiple components. During assembly, multiple separate components may be mechanically coupled together to form a singular housing. This process may increase both time and cost of manufacture. In addition, the mechanical coupling often becomes a structural weak point and/or an aesthetic blemish of a fully assembled device. 
     In one example, housings are formed in a clam shell structure. In such a process, two halves of the housing may be formed separately. After the halves are formed, the two halves of the housing are then assembled using an adhesive or similar mechanical process to hold the two halves together. As indicated above, this may be a costly additional step and the process leaves behind an unattractive seam between the two housing halves. 
     SUMMARY 
     Systems and methods for forming a housing of unitary construction are described herein. One embodiment may take the form of, a housing for electronic components including a major interior surface that defines an interior cavity. The housing may include a major exterior surface comprising at least a first surface and a second surface. The housing may include a major aperture extending from the interior cavity through the major interior surface and major exterior surface. The major aperture may pass through a portion of the first surface and the second surface. The major aperture may extend through a portion of but not the entirety of the at least the first surface and the second surface. The housing may be a single, unitary construction formed of a rigid material of substantially uniform thickness. The housing may be formed in one injection molding step. In further embodiments, the rigid housing for electronic components also includes at least one interior surface feature of the housing member configured to couple to electronic components. The major aperture of the housing may have a substantially L-shaped cross section. The major aperture of the housing may also include a receiving lip around the perimeter of the major aperture. The housing may include a retention cap configured to couple to the receiving lip such that the surface of the retention cap is flush with the at least first and second face of the exterior of the housing member. The retention cap may be flush with the exposed edge of the major aperture. The housing may include a surface feature on the interior surface configured to receive a screw. This surface feature may be molded with a threaded insert member, or in other embodiments, may be molded to receive a self-tapping screw. 
     In accordance with various embodiments, a method for forming a rigid housing of unitary construction may include providing a major internal mold assembly. Providing the major internal mold assembly may include providing a plurality of movable interior slides in a first position for forming an interior cavity of the housing with each slide having an extraction protrusion. The method may include providing a major external mold assembly. The major external mold assembly may include providing a plurality of movable components in a first position for forming a major external surface of the housing. A cavity may be formed between the major internal mold assembly and the major external mold assembly. The cavity may be configured for injecting resin to form the housing of unitary construction. Resin may be injected in the cavity between the major internal mold assembly and the major external mold assembly. This injection may form a major internal surface and a major external surface, respectively. The formation of the surfaces forms the housing of unitary construction. The major external mold assembly may mate with the extraction protrusion of each of the plurality of movable interior slides. A major aperture may be formed in the housing of unitary construction. The aperture may pass from the interior cavity through the interior surface and the exterior surface of the housing. The major aperture may be formed around the extraction protrusions of each of the movable slides. For example, the aperture formation may be located where the major external mold assembly mates with the extraction protrusion of each of the plurality of movable interior slides. This location may be proximal to the cavity formed between the major internal mold assembly and the major external mold assembly. A first moveable interior slide may be removed through the aperture formed in the housing of unitary construction. A second moveable interior slide may be moved within the formed housing of unitary construction toward the aperture and the second moveable interior slide may be removed through the aperture formed in the housing of unitary construction. The first movable exterior mold component may be removed. The housing of unitary construction may be removed from the tooling. 
     In accordance with various embodiments, a system for forming a rigid housing of unitary construction may include a major internal mold assembly comprising a plurality of movable interior slides. Each of the plurality of movable interior slides may have an extraction protrusion. The system may include a major external mold assembly having a plurality of movable components. The major internal mold assembly may be located internally to the major external mold assembly such that a housing cavity is formed between the major internal mold assembly and the major external mold assembly. The cavity may be configured to receive resin to form the housing. In response to the plurality of movable interior slides being assembled to form the major internal mold assembly the plurality of movable interior slides occupy at least a portion of an interior cavity within the major external mold assembly. The major external mold assembly may mate with the extraction protrusion of each of the plurality of movable interior slides. The plurality of movable interior slides may be movable within the major external mold assembly and may be configured to move out of the interior cavity. The plurality of movable interior slides may include extraction protrusions that extend out of the interior cavity and mate with an interior of the major external mold assembly. The plurality of movable interior slides may include a first slide, a second slide and a third slide, with the first and second slide engaged and the second and third slide engaged with both engagements being sufficiently tight to prevent resin form flowing between the plurality of movable interior slides. The engagement may allow for the plurality of movable interior slides to move relative to one another. The second slide may be located between the first slide and the third slide. The second slide may be sized and positioned such that it is operable to be moved out from between the first slide and the third slide. The first slide is sized and positioned such that it is operable to be moved out of the interior cavity by utilizing the space occupied by the second slide prior to the second slide&#39;s movement, while the third slide is still positioned in the interior cavity. The third slide is sized such that it is operable to be moved out of the interior cavity after the first slide and the second slide are removed. 
     Another embodiment may take the form of a housing, comprising: an injection-molded body defining a cavity therein; an aperture passing through the injection-molded body; wherein the largest cross-section of the interior cavity is larger than the largest cross-section of the aperture; and the injection-molded body is unitary. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  illustrates a parallel projection view of an example housing of unitary construction. 
         FIG. 1B  illustrates a rear view of an example housing of unitary construction. 
         FIG. 1C  illustrates a side view of an example housing of unitary construction. 
         FIG. 1D  illustrates a parallel projection view of an example housing of unitary construction illustrating an electric component inserted through an aperture in the housing. 
         FIG. 1E  illustrates a parallel projection view of an example housing of unitary construction. 
         FIG. 1F  illustrates a parallel projection view of an example housing of unitary construction. 
         FIG. 1G  illustrates a parallel projection view of an example housing of unitary construction. 
         FIG. 2  is a parallel projection view of an example housing of unitary construction. 
         FIG. 3  is a parallel projection view of an example housing of unitary construction, where an interior surface feature can be seen through a major aperture of the housing. 
         FIG. 4  is a parallel projection view of an example housing of unitary construction, where an interior surface feature can be seen through a major aperture of the housing. 
         FIG. 5A  illustrates a side view of an example housing of unitary construction with an example tooling insert extending therefrom. 
         FIG. 5B  illustrates a bottom view of the example housing of  FIG. 5A . 
         FIG. 5C  illustrates a cross section side view of an example housing of unitary construction with an example tooling insert extending therefrom. 
         FIG. 5D  illustrates a cross section side view of an example housing of unitary construction with an example tooling insert extending therefrom. 
         FIG. 5E  illustrates a cross section side view of an example housing of unitary construction with an example tooling insert extending therefrom. 
         FIG. 5F  illustrates a cross section side view of an example housing of unitary construction with an example tooling insert extending therefrom. 
         FIG. 5G  illustrates a cross section side view of an example housing of unitary construction with an example tooling insert extending therefrom. 
         FIG. 5H  illustrates a parallel projection view of an example housing of unitary construction with an example tooling insert extending therefrom. 
         FIG. 5I  illustrates a cross section side view of an example housing of unitary construction with an example tooling insert extending therefrom. 
         FIG. 6A  illustrates a side view of an example housing of unitary construction with an example tooling insert extending therefrom. 
         FIG. 6B  illustrates a cross section side view of an example housing of unitary construction with an example tooling insert extending therefrom. 
         FIG. 7A  illustrates a parallel projection view of an example injection molding tool for forming a housing of unitary construction. 
         FIG. 7B  illustrates a parallel projection view of an example top section of an injection molding tool for forming a housing of unitary construction. 
         FIG. 7C  illustrates a parallel projection view of an example bottom section of an injection molding tool for forming a housing of unitary construction. 
         FIG. 7D  illustrates a side cross section view of an example injection molding tool for forming a housing of unitary construction as viewed from section B-B in  FIG. 7A . 
         FIG. 7E  illustrates a side cross section view of an example injection molding tool for forming a housing of unitary construction as viewed from section B-B in  FIG. 7A . 
         FIG. 7F  illustrates a side cross section view of an example injection molding tool for forming a housing of unitary construction as viewed from section B-B in  FIG. 7A . 
         FIG. 7G  illustrates a side cross section view of an example injection molding tool for forming a housing of unitary construction as viewed from section B-B in  FIG. 7A . 
         FIG. 7H  illustrates a side cross section view of an example injection molding tool for forming a housing of unitary construction as viewed from section B-B in  FIG. 7A . 
         FIG. 7I  illustrates a side cross section view of an example injection molding tool for forming a housing of unitary construction as viewed from section B-B in  FIG. 7A . 
         FIG. 8A  illustrates parallel projection view of a portion of an example injection molding tool for forming a housing of unitary construction. 
         FIG. 8B  illustrates parallel projection view of a portion of an example injection molding tool for forming a housing of unitary construction in accordance with the cross sections of  FIG. 8C-J . 
         FIG. 8C  illustrates a side cross section view of an example injection molding tool for forming a housing of unitary construction as viewed from a section C-C in  FIG. 8B . 
         FIG. 8D  illustrates an alternative side cross section view of an example injection molding tool for forming a housing of unitary construction as viewed from a section C-C in  FIG. 8B . 
         FIG. 8E  illustrates an alternative side cross section view of an example injection molding tool for forming a housing of unitary construction as viewed from a section C-C in  FIG. 8B . 
         FIG. 8F  illustrates an alternative side cross section view of an example injection molding tool for forming a housing of unitary construction as viewed from a section C-C in  FIG. 8B . 
         FIG. 8G  illustrates an alternative side cross section view of an example injection molding tool for forming a housing of unitary construction as viewed from a section C-C in  FIG. 8B . 
         FIG. 8H  illustrates a sectional parallel projection view of an example injection molding tool for forming a housing of unitary construction. 
         FIG. 8I  illustrates an alternative side cross section view of an example injection molding tool for forming a housing of unitary construction as viewed from a section D-D in  FIG. 8G . 
         FIG. 8J  illustrates an alternative side cross section view of an example injection molding tool for forming a housing of unitary construction as viewed from a section D-D in  FIG. 8G . 
         FIG. 8K  illustrates a top view of a portion of an example injection molding tool for forming a housing of unitary construction highlighting the removal of inserts. 
         FIG. 8L  illustrates a parallel projection view of a portion of an example injection molding tool for forming a housing of unitary construction. 
         FIG. 8M  illustrates a parallel projection view of a portion of an example injection molding tool for forming a housing of unitary construction. 
         FIG. 9A  illustrates a parallel projection view of an example of the movable components of an interior mold for a housing of unitary construction. 
         FIG. 9B  illustrates a parallel projection view of an example of the movable components of an interior mold for a housing of unitary construction after a second component has been moved into a second position. 
         FIG. 9C  illustrates a parallel projection view of an example of the movable components of an interior mold for a housing of unitary construction after a first and second component have been moved into a second position. 
         FIG. 9D  illustrates a parallel projection view of an example of the movable components of an interior mold for a housing of unitary construction after a first and second component have been moved into a second position and a second minor component of the third major component has been moved into a second position, causing first and third minor components to compress. 
         FIG. 9E  illustrates parallel projection views of an example of an aperture mold assembly with a semitransparent molded housing overlay. 
         FIG. 9F  illustrates parallel projection views of an example of an aperture mold assembly with a semitransparent molded housing overlay. 
         FIG. 9G  illustrates a parallel projection view of an example of the movable components of an interior mold for a housing of unitary construction when assembled through an aperture mold assembly in a first position. 
         FIG. 9H  illustrates a parallel projection view of an example of the movable components of an interior mold for a housing of unitary construction when assembled through an aperture mold assembly in a first position, where movable external mold components are ready to be assembled around the interior mold. 
         FIG. 9I  illustrates a parallel projection view of an example of the movable components of an interior mold for a housing of unitary construction when assembled through an aperture mold assembly in a first position, where movable external mold components are assembled around the interior mold. 
         FIG. 9J  illustrates a parallel projection view of an example of the movable components of an interior mold for a housing of unitary construction when assembled through an aperture mold assembly in a first position, where movable external mold components are assembled around the interior mold and a portion of the external mold is illustratively transparent to reveal both a runner and a gate for an injection molding process. 
         FIG. 9K  illustrates a cross section view of  FIG. 12   a.    
         FIG. 9L  illustrates a parallel projection view of an example of a completed mold formed around the movable components of an interior mold for a housing of unitary construction when assembled through an aperture mold assembly in a first position, where movable external mold components are separated from the exterior surface of the formed mold. 
         FIG. 9M  illustrates a parallel projection view of an example of a completed mold formed around the movable components of an interior mold for a housing of unitary construction when assembled through an aperture mold assembly in a first position, where movable external mold components are separated from the exterior surface of the formed mold and a fixture has been coupled to the formed mold. 
         FIG. 9N  illustrates a parallel projection view of an example of a fixture coupled to a formed mold being removed at an angle over a third major internal component of the mold, with the first and second internal mold components removed. 
         FIG. 9O  illustrates a parallel projection view of an example of a housing of unitary construction with injection molding gate residue visible. 
         FIG. 9P  illustrates a parallel projection view of an example of a housing of unitary construction with injection molding gate residue visible. 
         FIG. 9Q  illustrates a parallel projection view of an example of a housing of unitary construction after gate residue has been removed and a minor aperture has been opened in the housing. 
         FIG. 9R  illustrates a parallel projection view of an example of a housing of unitary construction after gate residue has been removed and a minor aperture has been opened in the housing. 
         FIG. 10  illustrates a flow chart of an example process for forming a housing of unitary construction. 
         FIG. 11  illustrates a flow chart of an example process for forming a housing of unitary construction. 
         FIG. 12  illustrates a flow chart of an example process for disassembling a mold of unitary construction. 
     
    
    
     DETAILED DESCRIPTION 
     Introduction 
     Numerous consumer and non-consumer devices utilize housings to contain electronic components. As discussed herein and in accordance with various embodiments, a tooling system may be utilized in order to form a unitary housing structure that may house these various electronic components or serve similar purposes. 
     More particularly, an injection molding system may include a cavity that is configured to receive a plurality of internal slides. The cavity may be defined by one or more external tooling sections that cooperate to form the cavity (collectively, a “major exterior mold assembly”). The plurality of internal slides may form a major internal mold assembly and generally cooperate to define a cavity within a finished unitary housing structure, as well as an aperture through the unitary housing structure to provide access to this cavity. In accordance with various embodiments, the housing of unitary construction may be molded with a major internal mold assembly and a major exterior mold assembly meeting in a first position to form a cavity. 
     A resin may be injected into the cavity to form the unitary housing structure (or “housing”). To facilitate efficient removal of a molded housing, the major internal mold assembly and the major exterior mold assembly may be selectively movable and disassemblable. In various embodiments, a portion of the internal mold assembly may be removed from the interior cavity before the molded part is removed for further manufacturing processing. The major internal mold assembly may form an interior cavity of the unitary housing during the injection molding process. The major internal mold assembly may also form an exterior aperture in the unitary housing. After the molding process, the major internal mold assembly may be removed through the exterior aperture in the unitary housing. As discussed herein, the major internal mold assembly may have a larger cross section than the cross section of the exterior aperture in the housing. 
     Unitary Housings 
     Additionally, examples and embodiments described herein relate to geometries of housings of unitary construction that are more efficient to manufacture. Housings of unitary construction generally may have internal surface features intentionally placed for coupling to, and securing, electronic components to be inserted therein in a later product assembly process. The later assembly processes often involve the polishing away of undesirable flash, removing by a secondary process (e.g. CNC machining) excess gate or runner material left behind by the injection molding process, and creating minor apertures through the housing by similar or the same secondary processes. 
     The minor apertures in the housing may be configured to pass light through the housing from, for example, light emitted by the housed electronic components and that is to be viewed external to the housing. In various embodiments, the minor apertures in the housing may be configured to pass audio produced by the housed electronic components through the housing such that it may be better heard outside the housing. In various embodiments, the minor apertures in the housing may be configured to allow access to the housed electronic components, for example, access to a reset or power button is available external to the housing. In various embodiments, the minor apertures in the housing may be configured such that the housing, in a later process, can be coupled to an additional part. 
     Each of these operations, especially the processing of additional minor apertures, may add cost or delay to the manufacturing of each housing. Accordingly, various benefits may be achieved by co-locating internal surface features of the housing with the gates from the injection molding process such that the gates may be removed in the same process in which the minor apertures are later opened. In other embodiments, some internal surface features may be co-located with gates from the injection molding process in order to provide additional structural integrity around locations where apertures will be later opened. 
     A “unitary structure,” as described herein, refers to a housing in which the exterior surfaces are contiguous (e.g., are not separate but mechanically attached to one another to form a surface or component). A unitary structure may also be formed in a single manufacturing process. The housing of unitary construction may be formed, in certain embodiments, in a single injection molding process. In one example, the formation of the exterior surfaces may include the formation of the entire exterior surfaces of the molded housing. The entire exterior surface of a housing may not include caps or other features utilized to fill various apertures. The caps or other features may however constitute additional surfaces and not mechanical extensions or seams in the same surface. In another example, the formation of the exterior surfaces may include the formation of at least a portion of all of the exterior surfaces of the housing. For example, a box may have six sides. The box may have an aperture through one or more of the sides. The aperture may make one or more of the sides incomplete preventing the box from being enclosed. The six sides may be formed in the injection molding process. In various embodiments, the six sides may be seamless. The six sides may be contiguous with no mechanical attachments utilized to form the six sides. The six sides may all be formed at the same time in the same tool in a contiguous manner. 
     For example,  FIGS. 1-4  illustrate an example housing of unitary construction. In accordance with various embodiments and as illustrated in  FIGS. 1 a - c   , the housing may include a top surface  115   a , a front surface  115   b , a bottom surface  115   c , a back surface  115   d , a left surface  115   e , or a right surface  115   f . In accordance with various embodiments, as illustrated in  FIG. 2 , the housing  100  may include a major exterior surface  110  and a major aperture  130  which provides a location through which major internal mold assemblies may be inserted and removed during molding. The interior volume of the housing  100  may be visible through aperture  130 . The interior volume may be defined by the walls defined by a major internal surface  120  and the major exterior surface  110 . The housing  100  may be constructed of any material suitable for injection molding. For example, the housing may be made of a rigid material not subject to substantial deformation. 
     In accordance with various embodiments, as discussed above and illustrated in  FIGS. 1-4 , the housing may include one or more apertures. For example, a minor aperture  160  may pass through at least one surface such as left surface  115   e . In various embodiments, at least one aperture may pass through more than one surface. A major aperture  130  may pass through  115   a ,  115   b ,  115   f  and  115   d  forming an aperture surface  117 . By having the aperture in several surfaces but by leaving at least a portion of each of those surfaces, the housing may have a unitary construction. In accordance with various embodiments, as illustrated in  FIGS. 1-4 , the housing does not have seams where multiple portions of the housing are assembled to create the completed housing with surfaces  115   a - g . The housing may be a contiguous structure without the use of adhesives or mechanical attachments to connect portions of any of the walls  115   a - g.    
     The major aperture  130  may extend from a major interior surface  120  through the housing  100  to the exterior surface  110  through at least two faces  115   a  and  115   b  of the exterior surface. By extending through at least more than one face of the exterior surface, the perimeter of the major aperture may be defined by an area parallel to the first face  115   a  and an area parallel to the second face  115   b . The cross sectional opening of the major aperture  130  may be larger than the cross sectional of the largest slide utilized to form a portion of the interior cavity. The cross sectional opening may be smaller than the cross sectional of the largest slide combined with the cross section of the narrowest portion of any other additional slide utilized to form at least a portion of the interior cavity. 
     As illustrated in  FIGS. 1 d - g   , the housing  100  may be configured to receive and contain electronic components  180 . In various embodiments, electronic components  180  may be inserted through the major aperture  130  into the housing  100 . As such, the major aperture  130  may have a suitable cross section entrance to receive the electronic components  180 . The electronic components  180  may be inserted into the housing  100  in one or more sections. For example, a first electronic component may be inserted and then a second electronic component may be inserted connecting to the first electronic component. 
     As illustrated in  FIGS. 1A, 1E, and 1G , the housing  100  may include a retention cap  170 . The retention cap  170  having first and second exterior cap surfaces  172   a  and  172   b  that intersect at an elbow  174 . The retention cap  170  may mate with a receiving lip  119  formed around major aperture  130 , In this structure; the retention cap  170  may mount flush with the aperture surface  117 , Once mounted, the retention cap  170  may close the major aperture  130  and contain the electronic components  180  inside of the housing  100 , Thus, the retention cap  170  may be configured as an electronics retention cap. The retention cap  170  includes a protrusion  176  that extends outward from the first exterior cap surface  172   a  and a minor aperture  178  that extends through the second exterior cap surface  172   b  to the interior cavity. The housing is illustrated as being transparent in  FIGS. 1D, 1F and 1G  for purposes of clarity, although the housing is not necessarily transparent in any embodiment. 
     As illustrated in  FIG. 3 , the housing may have an interior surface  120 . Interior surface  120  may include interior surfaces which correspond to the opposing wall surfaces of  115   a - f . For example, interior surface  120  may comprise interior back surface  125   d  (corresponding to back surface  115   d ) and interior bottom surface  125   c  (corresponding to bottom surface  115   c ). Interior surface  120  may also comprise interior feature  140 . Interior surface feature  140  may be located on or through the bottom surface  125   c , as can be seen through the major aperture  130  of the housing in  FIG. 3 . As illustrated in  FIG. 4 , the housing  100  may comprise an additional interior surface feature  140 . For example, the additional interior surface feature can be seen through a major aperture  130  of the housing  100 . 
     In accordance with one embodiment, as illustrated in  FIGS. 5-8  a tooling apparatus may be operable to assemble and separate inside of a molded part allowing the tool to form an internal cavity that is larger than the aperture through which the internal mold assembly is inserted. This internal mold assembly may include a relatively small number of moving parts, for example three. The system may include a major external mold assembly and a major internal mold assembly that are assembled together in a first position to form the cavity with the geometric features of the housing  100 . 
     Mold Assembly with Internal Slides 
     As illustrated in  FIGS. 5A-5D , a major internal mold assembly may include a plurality of tooling slides for the formation of the interior cavity of the housing  100 . The plurality of tooling slides may be independently and selectively movable relative to one another. The major internal mold assembly may include a first major interior slide  310 , a second major interior slide  320 , and a third major interior slide  330 . The major internal mold assembly may extend from major aperture  130  after forming the housing  100 . 
     As illustrated in  FIG. 5B , the first major interior slide  310 , the second major interior slide  320 , and the third major interior slide  330  may extend through the aperture at the same time and engage one another, although they may enter or exit the aperture at different times. In accordance with various embodiments, the second major interior slide  320  may engage the first major interior slide  310  through a first engagement feature  327 . The second major interior slide  320  may engage the third major interior slide  330  through a second engagement feature  329 . The engagement may be any process or feature for engaging two movable tooling slides. For example, as illustrated in  FIG. 5B  the engagement features may include dovetail connections with an engagement groove and an engagement protrusion. It may be noted that each of the first major interior slide  310 , the second major interior slide  320 , and the third major interior slide  330  may include a receiving feature, a protruding feature or any combination of the same, and so are not limited to dovetail connections. 
     In accordance with various embodiments, the major internal mold assembly may be configured to be removed from the interior of the housing  100  after the housing  100  has been molded. This may be accomplished by removing each interior slide that make up the major internal mold assembly one at a time (or substantially removing them one at a time). For example, as illustrated in  FIG. 5C  and discussed above, the first major interior slide  310 , the second major interior slide  320  and the third major interior slide  330  may be independently movable. The second major interior slide  320  may be moved relative to the first major interior slide  310  and the third major interior slide  330  laterally. For example,  FIG. 5C  illustrates arrow  1  which may represent the order and path of travel of the second major interior slide  320  relative to the first major interior slide  310  and the third major interior slide  330 . Arrow  1  of  FIG. 5C  may represent a second position of the major internal mold assembly. Arrow  2  may represent the order and path of travel of the third major interior slide  330  relative to the first major interior slide  310  and the second major interior slide  320 . Arrow  2  of  FIG. 5C  may represent a third position of the major internal mold assembly. Arrow  3  may represent the order and path of travel of the first major interior slide  310  relative to the second major interior slide  320  and the third major interior slide  330 . Arrow  3  of  FIG. 5C  may represent a fourth position of the major internal mold assembly. 
     As illustrated in  FIG. 5D , the major internal mold assembly may be positioned within the housing  100  after the housing  100  has been molded. Portions of the major internal mold assembly may protrude from the housing  100  through the major aperture  130 . The portions of the major internal mold assembly that may protrude from the housing  100  may be utilized to extract each of the plurality of tooling slides from the housing  100  after molding is complete. For example, the first major interior slide  310  may include a first extraction protrusion  315 . The first extraction protrusion  315  may be located outside of the molded housing  100  and within the injection tooling system. The first extraction protrusion  315  may be configured to receive a mechanical force to extract the first major interior slide  310  from within the molded housing  100 . The second major interior slide  320  may include a second extraction protrusion  325 . The second extraction protrusion  325  may be located outside of the molded housing  100  and within the injection tooling system. The second extraction protrusion  325  may be configured to receive a mechanical force to extract the second major interior slide  320  from within the molded housing  100 . The third major interior slide  330  may include a third major extraction protrusion  335 . The third extraction protrusion  335  may be located outside of the molded housing  100  and within the injection tooling system. The third extraction protrusion  335  may be configured to receive a mechanical force to extract the third major interior slide  330  from within the molded housing  100 . 
     As illustrated in  FIG. 5E , the second major interior slide  320  may be configured to move relative to the first major interior slide  310  and the third major interior slide  330  opening a space within housing  100  between the first major interior slide  310  and the third major interior slide  330 . The second major interior slide  320  may include various features that allows it to form a portion of the housing  100 . For example, the second major interior slide  320  may include a front surface and a back surface. For example, a front surface  321  may form the front interior wall of housing  100 . The back surface (on the opposite side of front surface  321  on the second major interior slide  320 ) may form a portion of the back interior wall  125   d  of housing  100 . Additionally, a first surface  134  may form a portion of an interior wall of housing  100 , a second surface  138  may form a portion of a second interior wall of housing  100 , and a transition point  136  may form a transition between the first surface  134  and the second surface  138  to form a transition within housing  100 . The second major interior slide  320  may include various features that allow it to engage with and move relative to the first major interior slide  310  and the third major interior slide  330 . For example, the second major interior slide  320  may include engagement groove  132 , (this engagement feature may also be an engagement protrusion in accordance with various embodiments). For example, the second major interior slide  320  may include engagement protrusion  139  (this engagement feature may also be an engagement groove in accordance with various embodiments). 
     As illustrated in  FIG. 5F , the first major interior slide  310  may be configured to move relative to the third major interior slide  330  opening additional space within housing  100 . The first major interior slide  310  may include various features that allow it to form a portion of the housing  100 . For example, a front surface  311  may form the front interior wall of housing  100 . The back surface (on the opposite side of front surface  311  on the first major interior slide  310 ) may form a portion of the back interior wall  125   d  of housing  100 . Additionally, a first surface  312  may form a portion of an interior wall of housing  100 , a second surface  316  may form a portion of a second interior wall of housing  100 , and a transition point  314  may form a transition between the first surface  312  and the second surface  316  to form a corresponding transition within housing  100 . The first major interior slide  310  may include various features that allow it to engage with and move relative to the second major interior slide  320 . For example, the first major interior slide  310  may include engagement protrusion  318  (this engagement feature may also be an engagement groove in accordance with various embodiments). 
     As illustrated in  FIG. 5G , the third major interior slide  330  may be configured to move out of the housing  100  major aperture  130 . The third major interior slide  330  may occupy the entirety of the cross section of the major aperture  130  indicated by arrows W in  FIG. 5G . This geometry of the third major interior slide  330  may be greater than either of the second major interior slide  320  or the first major interior slide  310 . The first major interior slide  310  may have a maximum width illustrated by arrow Y (as illustrated in  FIG. 5G ). This width may be less than the width W minus the width of the portion of the third interior slide  330  that occupies the major aperture  130  while the third interior slide  330  is seated in the cavity as it would be during the injection molding process. (i.e. the first position discussed above) The second major interior slide  320  may have a maximum width illustrated by arrow Z (as illustrated in  FIG. 5G ). This width may be approximately the width of W minus the width of the portions of the third interior slide  330  and the first interior slide  310  that occupy the major aperture  130  while the third interior slide  330  and the first interior slide  310  is seated in the cavity as they would be during the injection molding process. (i.e. the first position discussed above) Stated another way, the first major interior slide  310  is sized and positioned such that it is operable to be moved out of the interior cavity while the third major interior slide  330  is still positioned in the interior cavity, wherein the third major interior slide  330  is sized such that it is operable to be moved out of the interior cavity after the first major interior slide  310  and the second major interior slide  320  are removed. In various embodiments, the procedure of removing the first major interior slide  310  and the third slide may be interchangeable. For example, the size of the third major interior slide  330  could not be maximized (reducing the resulting size of the cavity it can form in the injection molding process) but instead having the first major interior slide  310  and the third major interior slide  330  the same size such that after the second major interior slide  320  is removed either the first major interior slide  310  or the third major interior slide  330  can be removed next. 
     In accordance with various embodiments, the first major interior slide  310 , the second major interior slide  320  and the third major interior slide  330  together form the interior cavity of housing  100 . The first major interior slide  310  and the third major interior slide  330  may form the corners of the housing where the exterior surfaces  115   a/e c/f  meet. The width of the first major interior slide  310  (expressed by X) and the third major interior slide  330  may be less than distance W. As such the distance from the aperture to the corners formed by the intersection of the bottom surface  115   c  and right surface  115   f  (shown as line X in  FIG. 5G ) and the corner formed by intersection of the top surface  115   a  and the left surface  115   e  may be less than the major aperture opening. In various embodiments, one of the corners formed (e.g. either  115   a  and  115   e  or  115   c  and  115   f ) may be approximately the same as the cross section distance of major aperture  130  (i.e. width was illustrated in  FIG. 5G ). 
     In accordance with various embodiments, the third major interior slide  330  may include various features that allow it to form a portion of the housing  100 . For example, a front surface  331  may form the front interior wall of housing  100 . The back surface (on the opposite side of front surface  331  on the third major interior slide  330 ) may form a portion of the back interior wall  125   d  of housing  100 . Additionally, a first surface  332  may form a portion of an interior wall of housing  100 , a second surface  336  may form a portion of a second interior wall of housing  100 , and a transition point  334  may form a transition between the first surface  312  and the second surface  316  to form a corresponding transition within housing  100 . The third major interior slide  330  may include various features that allow it to engage with and move relative to the second major interior slide  320 . For example, the third major interior slide  330  may include engagement groove  338  (this engagement feature may also be an engagement protrusion in accordance with various embodiments). 
     In accordance with various embodiments, the major interior slides  310 ,  320 , and  330  may be retained by a ring  307  as illustrated in  FIG. 5H  and  FIG. 5I . Ring  302  may be located in a position suitable to form  117  in the housing. A first ring surface  308  may form a portion of the aperture surface  117  and a second ring surface  309  may form another portion of the aperture surface  117 . The ring  307  may also be sized sufficient to compress the major interior slides  310 ,  320 , and  330  together as illustrated in the cross section of  FIG. 5I . The ring  307  may aid in maintaining close tolerance between the major interior slides  310 ,  320 , and  330  to limit any housing material from seeping between the major interior slides  310 ,  320 , and  330  during the injection molding process. The opening in the ring  307  may correspond to the major aperture  130 . 
     In accordance with various embodiments, the major internal mold assembly may be removable from the major aperture  130  in a variety of directions. For example  FIGS. 5A-I  illustrate the various slides (e.g. first major interior slide  310 , second major interior slide  320 , and third major interior slide  330 ) extracted in a direction that is not parallel to any of the walls housing walls. In another example, as illustrated in  FIGS. 6A-B , one or more of the various slides (e.g. a first major interior slide  610 , a second major interior slide  620 , and a third major interior slide  630 ) may be removed parallel to at least one of the walls of the housing  100 . The second major interior slide  620  may be removed at an angle to the housing  100  walls according to arrow  1 . The first major interior slide  610  may be removed from housing  100  parallel with at least one wall according to arrow  2 . The third major interior slide  630  may be removed from housing  100  parallel with at least one wall according to arrow  2 . 
     In accordance with various embodiments, the various slides (e.g. a first major interior slide  610 , a second major interior slide  620 , and a third major interior slide  630 ) may be sized and configured in any way to fill the interior volume of housing  100 . For example, the first major interior slide  610  may be larger or smaller than either of the other interior slides. The second major interior slide  620  may be larger or smaller than either of the other interior slides. The third major interior slide  630  may be larger or small than either of the other interior slides. Any combination of size and shape may be used to obtain the sought after size and shape of the housing  100 . Aperture  130  and the various slide shapes and sizes may be varied in order to allow the various slides to be extracted through aperture  130  while forming an interior cavity for the housing  100 . 
     In accordance with various embodiments, the various slides (e.g. the first major interior slide  610 , and the third major interior slide  630 ) may include additional features for forming other aspects of the housing  100 . For example, the first major interior slide  610  may include a lip feature  613  that corresponds to the retention lip  119 . As such, the first major interior slide  610  may be configured to form the retention lip  119 . The third major interior slide  630  may include a lip feature  633  that also corresponds to the retention lip  119 . As such, the third major interior slide  630  may be configured to form the retention lip  119 . 
     Injection Molding Tool with Simple Interior Slides 
     In accordance with the various embodiments, as discussed herein, the major internal mold assembly may be a portion of an injection molding tool. As illustrated in  FIGS. 7A-I , an injection molding tool may include a lower exterior mold assembly  710  and an upper exterior mold assembly  720 . In various embodiments, the injection molding tool may include external mechanical actuators. For example, the injection molding tool may include a hydraulic actuator  790  and hydraulic cylinder  792 . The injection molding tool may receive a resin from an injection gate  721  which may be delivered by injection pump to an internal cavity in which the housing  100  is formed. The injection gate  721  may be configured for filling the housing cavity with the resin. 
     As illustrated in  FIG. 7B , an upper exterior mold assembly  720  may include a molding surface  723 , and a molding surface  725 . The molding surfaces  723  and  725  may be configured to form outer surfaces of the housing  100 . For example, molding surface  723  may form the bottom surface  115   c . Molding surface  725  may form the left surface  115   e.    
     In various embodiments, the upper exterior mold assembly  720  may include a plurality of lances for engaging the lower exterior mold assembly  710 . For example, the upper exterior mold assembly  720  may include one or more of a first lance  726 , a second lance  728 , a third lance  722 , or a fourth lance  724 . The lances may be configured to engage exterior slides in the lower exterior mold assembly  710 . As the first lance  726 , the second lance  728 , the third lance  722 , or the fourth lance  724  engage the lower exterior mold assembly the lances may compress exterior slides together to aid in forming the cavity that forms the housing  100 . 
     As illustrated in  FIGS. 7C and 7D , a lower exterior mold assembly  710  may include a lower core plate  753 , an inner core plate  755 , a first secondary slide  708 , a second secondary slide  713  or a plurality of lance receptacles for engaging the upper exterior mold assembly  720 . For example, the lower exterior mold assembly  710  may include one or more of a first lance receptacle  732 , a second lance receptacle  742 , a third lance receptacle  752 , or a fourth lance receptacle  762 . The first lance receptacle  732  may be an aperture in a first external slide  730 . The first external slide  730  may have a molding surface  717  which forms an exterior surface of the housing  100 . For example, the molding surface  717  may form the front surface  115   b  of the housing  100 . The second lance receptacle  742  may be an aperture in a second external slide  740 . The second external slide  740  may have a molding surface  716  which forms an exterior surface of the housing  100 . For example, the molding surface  716  may form the back surface  115   d  of the housing  100 . The third lance receptacle  752  may be an aperture in a third external slide  750 . The third external slide  750  may have a molding surface  711  which may form an exterior surface of the housing  100 . For example, the molding surface  711  may form the top surface  115   a  of the housing  100 . The fourth lance receptacle  762  may be an aperture in a fourth external slide  760 . The fourth external slide  760  may have a molding surface  712  which forms an exterior surface of the housing  100 . For example, the molding surface  712  may form the left surface  115   e  of the housing  100 . As discussed above, each of the lances may be configured to engage their respective receptacles forcing the respective slides to compress toward the center of the tool. 
     In accordance with various embodiments, the cavity for the housing  100  may nested in the injection molding tool in a verity of ways. For example, as illustrated in  FIG. 7D , the upper exterior mold assembly  720  the exterior surface slide  750  and the exterior surface slide  760  are utilized to form the exterior surfaces  115   e ,  115   c  and  115   f  (see e.g.  FIGS. 1A-C ). It may be noted, as seen in  FIG. 7D , that the upper exterior molds assembly  720  forms a plurality of the sides (e.g. left side  115   e  and right side  115   c    FIGS. 1A-C ) of housing  100  and the exterior surface slide  750  and the exterior surface slide  760  form a single side of housing  100  each. 
     As illustrated in  FIG. 7D , as indicated above, the lower exterior mold assembly  710  may include the first secondary slide  708  or the second secondary slide  713 . The first secondary slide  708  may be positioned to mate with the first major interior slide  310 . The first secondary slide  708  may also support the third external slide  750  when the upper injection assembly  720  and the lower exterior mold assembly  710  are mated together during the injection molding process. The first secondary slide  708  may also receive the third lance  722  into a secondary slide receptacle  715  which is an aperture within the upper portion of the body of the first secondary slide  708 . The second secondary slide  713  may be positioned to mate with the third major interior slide  330 . The second secondary slide  713  may also support the fourth external slide  760  when the upper injection assembly  720  and the lower exterior mold assembly  710  are mated together during the injection molding process. The second secondary slide  718  may also receive the fourth lance  724  into a secondary slide receptacle  714  which is an aperture within the upper portion of the body of the second secondary slide  713 . 
     As illustrated in  FIG. 7D , as indicated above, the lower exterior mold assembly  710  may include the lower core plate  753 , the lower exterior mold assembly  710  may also include the inner core plate  755 . The inner core plate  755  may be positioned between the lower core plate  753  and the second secondary slide  713 . The inner core plate  755  may provide support to second secondary slide  713  or hydraulic cylinder  792 . The lower core plate  753  may be positioned below the inner core plate  755 . The lower core plate  753  may provide support to a core block  743 . The lower core plate  753  may be in communication with the second major interior slide  320 . The core plate  753  may be directly fixed to the second major interior slide  320 . Alternatively, the core plate  753  may be attached to the second major interior slide through an intermediary slide. The core plate  753  may have an aperture extending through the core plate  753  such that an ejector block  733  may extend through the lower core plate  753  and contact the third major interior slide  330 . 
     As illustrated in  FIG. 7E , the lower core plate  753  may be configured to be removable from the rest of the injection molding tool. Being attached to the second major interior slide  320 , removal of the core plate may additionally with draw the second major interior slide  320  from the interior of the injection molding cavity and the interior of housing  100 . The lower core plate  753  may be configured to slide down the ejector block  733  which stays in place during the removal of the lower core plate  753 . 
     As illustrated in  FIG. 7E , the hydraulic cylinder  792  may be configured to extend in the direction of arrow  1  illustrated in  FIG. 7E . An engagement between the first major interior slide  310  and the hydraulic cylinder  792  may cause the first major interior slide  310  to slide toward the third major interior slide  330 . The first major interior slide  310  may be able to contact the third major interior slide  330 . In this position the first major interior slide  310  may be operable to be pulled down and extracted from housing  100 . 
     As illustrated in  FIG. 7G , the third external slide  750  and the fourth external slide  760  may be translated laterally away from the housing  100  along arrows  1  and  2  respectively. This movement of the third external slide  750  and the fourth external slide  760  may remove the mold from the top surface  115   a  and the right surface  115   f  exposing them to the environment outside of the injection molding tool. The upper injection assembly  720  may be translated up and away from the housing  100 . This movement of upper injection assembly  720  may remove the mold from the left surface  115   e  and the bottom surface  115   c  exposing them to the environment outside. 
     As illustrated in  FIG. 7H , the ejector block  733  may be inserted into the mold assembly toward housing  100 . The ejector block  733  may be inserted in the direction of arrow  1  as illustrated in  FIG. 7H . As the ejector block  733  may contact the third major interior slide  330 , the third major interior slide  330  may also be forced up through the lower external mold assembly. With the third major interior slide  330  still located in the housing  100 , the housing  100  may be lifted up out of the lower external mold assembly along arrow  2  as illustrated in  FIG. 7H . Once the housing is lifted up and out of the lower external mold assembly the housing  100  may be removed off of the third major interior slide  330  in the direction of arrow  1  as illustrated in  FIG. 7I . 
     Alternatively, the injection tool may have the various components arranged to form housing  100  utilizing different injection molding plates and potentially limiting the parts of the tool used to form the exterior surfaces of housing  100 . For example, as illustrated in  FIG. 8A , the injection tooling may include an upper plate  803 , a lower plate  805 , a first exterior plate  810 , and a second exterior plate  820 . The upper plate  803  and the lower plate  805  may form the front surface  115   b  and the back surface  115   d  (the front and back surfaces as shown in  FIGS. 1-4 ). The injection tool may also include the first major interior slide  310 , the second major interior slide  320 , and third major interior slide  330 . Similar to the embodiments discussed above in relationship to  FIGS. 5H and 5I , the tool may comprise ring  307  which may form the aperture of housing  100  or retain the major interior slides  310 ,  320 , and  330 . However it may be noted that the inclusion is merely one embodiment that may variously by combined with or separated from any of the other embodiments as discussed herein. For example,  FIGS. 8B-8J  do not specifically mention the ring but instead the major interior slides  310 ,  320 , and  330  form the aperture of housing  100  and engage one another without the added support of ring  100 . However, the ring  100  may still be included as shown in  FIGS. 8K-8M . 
       FIG. 8B  illustrates the first exterior plate  810  and the second exterior plate  820  in the absence of the upper plate  803  and the lower plate  805 . The first exterior plate  810  and the second exterior plate  820  may each form a plurality of the sides of housing  100 . In this example, the first exterior plate  810  and the second exterior plate  820  are each configured to be separable from housing  100 . The second exterior plate  820  may form bottom surface  115   c  and right surface  115   f . The first exterior plate  810  may form left surface  115   e  and top surface  115   a.    
     In accordance with various embodiments, as discussed above and illustrated in  FIG. 8C  the injection molding tool may also include a plurality of interior surface slides such as the third major interior slide  330 , the second major interior slide  320 , and the first major interior slide  310  which form the major interior mold assembly. As discussed above, the third major interior slide  330  and the second major interior slide  320  may be engaged with one another. The second major interior slide  320  and the first major interior slide  310  may be engaged with one another. Both engagements may be sufficiently tight to prevent resin form flowing between each of the slides but still allowing for each of the slides to move relative to one another. The tool may also include slide areas which may be utilized to move slides within the injection tool. For example, a slide area  838  may be located on one or more sides of the first major interior slide  310 . The slide area  838  may allow the first major interior slide  310  to move relative to a third major exterior slide  830  within the injection molding tool. This movement may enable the first major interior slide  310  to exit the housing  100  after the housing is formed. 
     As illustrated in  FIG. 8D  the first exterior plate  810  and the second exterior plate  820  may be separable exposing the housing  100  after molding is completed. The separation may occur along the directions of arrows  1  and  2  as shown in  FIG. 8D . The second major interior slide  320  may be pulled out of the housing  100  along the direction of the arrow illustrated in  FIG. 8E . The first major interior slide  310  may be pulled out of the housing  100  along the direction of the arrow illustrated in  FIG. 8F . In this movement, the first major interior slide  310  may occupy the slide area  838  set aside for this translation of the first major interior slide  310 . The third major exterior slide  830  may be moved along the direction of the arrow illustrated in  FIG. 8G . The movement of the third major exterior slide  830  may pull the first major interior slide  310  out of the housing  100  in the direction of the arrow illustrated in  FIG. 8G . The third major interior slide  330  may push (or pull) the housing  100  away from the other injection molding tool portions already separated. The movement of the housing  100  may be along the arrow illustrated in  FIG. 8H . In this motion, the housing  100  may be suspended and/or touching the third major interior slide  330 . The housing  100  may be removed from the third major interior slide  330  by translating the housing  100  in the direction of the arrow in  FIG. 8I  and then in the direction of the arrow in  FIG. 8J . 
     As discussed above and illustrated in  FIGS. 8K-8M , the injection molding tool may include ring  307 . By utilizing ring  307  the major interior slides  310 ,  320 , and  330  may be maintained together in tighter tolerances. After injection molding housing  100 , the ring may be separated from the housing and other portions of the tool. Until major interior slides  310 ,  320 , and  330  are entirely removed from the interior of the ring  307  the ring  307  may not be entirely separated from the injection molding tool. However, in accordance with various embodiments, once major interior slide  320  is removed from the interior of the housing  100  (along arrow A as shown in  FIG. 8K ) and out of ring  307 , the ring  307  may be separated from the injection molding tool. In separating the ring  307  from the injection molding tool major interior slides  320  and  330  may be moved towards the interior of ring  307 . In various examples, the ring  307  may be separated from the aperture of housing  100  along arrow D by 1 mm. Major interior slide  330  may move along arrow B (in one example arrow B may be 57 degrees off a line which can be depicted by direction of arrow A) and be removed from ring  307 . Major interior slide  310  may move along arrow C (in one example arrow C may be 37 degrees off a line which can be depicted by direction of arrow A) and be removed from ring  307 . After the major interior slides  310 ,  320 , and  330  are removed, the  810  and the second exterior plate  820  may be separated as shown in  FIG. 8L . Specifically  810  may be moved along arrow A and  820  may be moved along arrow B as shown in  FIG. 8L . Subsequently the housing  100  may be separated from the lower plate  805 , ring  307 , the first exterior plate  810 , and second exterior plate  820  along arrow A, as shown in  FIG. 8M . 
     Injection Molding Tool with Compound Interior Slides 
     In accordance with another embodiment, as illustrated in  FIGS. 9A-R , a major internal mold assembly operable to compress in on itself by utilizing compound interior slides. The additional compression operation of a major internal mold assembly may allow for larger internal features in a housing to be formed using a smaller aperture. Tooling utilizing a major internal mold assembly may operate or have similar features as tooling discussed above. Some of these similar feature and additional features may be discussed below with respect to embodiments directed to compressible internal mold assemblies. 
       FIG. 9A  illustrates an example of a first position of an embodiment of a major internal mold assembly. The major interior surface mold assembly  200  may be comprised of a plurality of movable components. As indicated the plurality of movable components may be selectively movable. The interior surface assembly  200  may comprise three major independently moveable slides. A first major independently movable interior surface slide  210  contours the interior surface of at least a first interior face of the first housing member, but may contour a portion of interior faces adjacent to the first interior face. The first major slide  210  may also form at least one interior surface feature  240  suitable for coupling electronic devices to the interior geometry of the faces the first major slide  210  contours. A second major independently movable interior surface slide  220  may include a dovetail  250  which may engage with the first major slide  210 . This may configure the second slide  220  to freely slide along the face of the first major slide  210 . The second major slide  220  may contour additional area of the interior faces adjacent to the first face. 
     Each of the major slides  210 ,  220 , and  230  may be considered compound slides as they may have movable subcomponents. The inclusion of these movable subcomponents as discussed herein may allow the major slides  210 ,  220 , and  230  to exit through a smaller aperture in the completed housing of unitary construction while being able to form a larger interior volume in the housing of unitary construction. 
     A first minor slide  234 , second minor slide  232  and third minor slide  236  may couple together to form a third major independently movable interior surface slide  230 . The first minor slide  234  may connect with a dovetail coupling  260  to the second minor slide  232  or third minor slide  236 . The width of the first slide  234  may taper parallel to the dovetail coupling  260  such that when the first minor slide  234  slides along the dovetail coupling  260  the second  232  and third minor  236  slides may compress together. When the three minor slides ( 232 ,  234 ,  236 ) are in a first position (e.g.  FIG. 9A ), the third major slide  230  forms at least a second interior face of the first housing member  100  (not show in  FIG. 9A ), and may also contour a portion of interior faces adjacent to the first interior face. The third major slide  230  may also form at least one interior surface feature  240  suitable for coupling electronic devices to the interior geometry of the faces the third major slide  230  contours. 
       FIG. 9B  illustrates an example of a second position companion to the embodiment of  FIG. 9A . In the embodiment as illustrated, the first major internal surface slide  210  is angled at the interface with the second major interior surface slide  220 . The second major independently movable slide  220  may slide down the dovetail coupling  250  along the angled faces between the first major interior surface slide  210  and second major interior surface slide  220 . 
       FIG. 9C  illustrates a third position. Which illustrates that the first major interior surface slide  210  and second major interior surface slide  220  may slide at the same time at an angle parallel to the outward facing major face of the first major slide  210 , or at such an angle as to remove the mold of interior surface feature  240  without exerting stress on a molded interior surface feature  140  (see e.g.  FIG. 3 ). 
       FIG. 9D  illustrates an example of a fourth position. For example, the first major interior surface slide  210  and second major interior surface slide  220  may slide at the same time at an angle parallel to the outward facing major face of the first major slide  210 , or at such an angle as to remove the mold of interior surface feature  240  without exerting stress on the molded interior surface feature  140  (see e.g.  FIG. 3 ). In addition, the first minor slide  234  may be slid along the tapered dovetail coupling  260  toward the vacancy created by the removal of the first major slide  210  and second major slide  220 . As a result of the tapered coupling  260 , the first minor slide  232  and third minor slide  236  are compressed toward one another. The compression of minor slides  232  and  236  and the movement of minor slide  234  may cause the third major slide  230  to compress along its width. The movement and compression of the third major slide  230  also permits any surface feature molds (e.g. surface feature mold  240 ) to be removed without exerting stress on a molded interior surface feature  140  (see e.g.  FIG. 4 ). 
     One of ordinary skill in the art will appreciate that  FIGS. 9A-D  are presented as showing a progression of positions of an interior mold as it is being removed from an already molded housing  100  as show in  FIGS. 2-4 . I may be appreciated that additional mold components may be utilized for a complete mold cavity but are not shown in  FIGS. 9A-D  so that the interior mold component movements may be more clearly understood. On of ordinary skill in the art will understand how to utilized the tooling discussed herein and apply the subject matter. 
     As illustrated in  FIGS. 9E-F , a major aperture mold assembly  300  may be used to contour the geometry of major aperture  130  of the housing  100 . The aperture mold has a rotated L-shaped profile, but those skilled in the art will recognize that the aperture may be of an arbitrary shape. The major aperture assembly  300  is sized such that when in the first position as shown in  FIG. 9A , major interior mold slides  210 ,  220  and  230  fit within and through the major aperture  300  to form the inverse of the interior surface  120  (see e.g.  FIGS. 3-4 ). The housing is shown as transparent in  FIG. 9F  to facilitate the view of the major aperture. 
     As illustrated in  FIG. 9G , the interior mold slides  210 ,  220  and  230  may be assembled through the aperture mold assembly  300  in the first position as shown in  FIG. 9A . The aperture mold assembly may be exactly the width of the interior mold assembly  200  to provide as tight a fit as possible between the parts. As illustrated in  FIG. 9H , a number of movable external mold components  410  may be positioned around the other mold components ( 200  and  300 ) in order to complete the interior and exterior geometry of the mold cavity. Together, external mold components  410  join together to contour the exterior surface of the mold cavity as exterior mold  400 . As further illustrated in  FIG. 9H , the foremost external mold component  410  has been made slightly transparent so that the injection molding runner  420  and gate  430  are also visible. Both runner  420  and gate  430  are hollow paths through which mold material may be injected. During the molding process, a certain amount of mold material is injected through runner  420  and gate  430  into the cavity created by the complete assembly of the mold. In various embodiments, the injection molding tool may include five external mold components as illustrated in  FIG. 9H , four of which contour a single external face, the foremost contouring two external faces. One skilled in the art will recognize that fewer than five external mold components may be utilized or more than five external mold components may be utilized. For example, some of the mold components may be combined into a single part in order to contour more than one face or edge. Although  FIG. 9H  illustrates the exterior mold components  410  contouring substantially flat faces and corners, one of ordinary skill can further appreciate that arbitrarily shaped exteriors or corners may be molded as well. 
     In various embodiments, exterior mold components  410  may be set in place along a path perpendicular to the face each component contours. In other embodiments, exterior mold components  410  may be angled into place or, in other embodiments, slid into position parallel the face each component contours. In further embodiments, exterior mold components  410  may also be rotated into place. One of skill in the art will appreciate that the path the exterior mold components  410  take while being set is arbitrary and may be changed. One of skill will further appreciate that independent external mold components may be set in different ways. 
       FIG. 9I  illustrates an example of a closed mold ready for injection. As the mold is closed, the cavity created by all three mold components (interior mold  200 , aperture mold  300 , exterior mold  400 ) is not visible.  FIG. 9J  is a companion figure to  FIG. 9I , with exception that the foremost external mold component  410  is illustrated transparently. In this way, the mold cavity  600  is visible. As illustrated in  FIG. 9K , the wall thickness of the mold cavity  600  may be determined by the position of the exterior mold components  410 . As demonstrated, the wall thickness of mold cavity  600  is not necessarily uniform. In various embodiments wall thickness may be uniform. One of ordinary skill can appreciate that wall thickness for the mold cavity may arbitrarily differ throughout the geometry of the mold. 
     Once mold material is injected through runner  420  and gate  430  into the mold cavity  600 , the housing of unitary construction  100  has been formed as is ready to be removed for further processing. As illustrated in  FIG. 9L , the external mold components  410  may be removed in the order they were set. In other embodiments, external mold components  410  may be removed in a different order. One of ordinary skill will appreciate that as with setting the external mold components, removal path and order of external mold components may be accomplished in a variety of orders. As further illustrated in  FIG. 9L , the gate residue  150  may be present if a cold runner injection molding process is used. As the gate residue may not provide an aesthetically or functionally please external geometry, it may be removed in a later process. As shown in  FIG. 9L , the interior mold assembly  200  may still be assembled within the molded housing  100 . 
     After the housing  100  has been molded and is prepared to be removed for further processing both the external and internal mold components may be positioned such that the newly molded housing may be separated without damage. In accordance with various embodiments, after external mold components are removed as illustrated in  FIG. 9L , a fixture  500  is coupled to the housing  100  ( FIG. 9M ). The fixtures  500  provides stability to the housing  100  as internal mold slides  210  and  220  are removed and component  230  is compressed in the sequence shown in  FIGS. 9A-D . In certain other embodiments, stability for the housing  100  is provided by the external mold assembly  400  during the removal and compression sequence of the internal mold components in  FIGS. 9A-D . In various embodiments, the fixture  500  may be coupled to the housing  100  before all external mold components  410  are removed. 
     As illustrated in  FIG. 9N , the injection molding tool may have a final position for the slides  210 ,  220  and  230  ( 232 ,  234 , and  236 ) after the independent movements shown in  FIGS. 9A-D . As a result, there may be sufficient space provided by the molded aperture  130  (see e.g.  FIGS. 2-4 ) that the housing  100  may be separated from internal mold  230 . In this way, the internal mold component  230  is not removed from the aperture assembly  300  during the separation of housing  100  by fixture  500 .  FIGS. 9O-9P  illustrate examples of the molded housing  100  after molding but before final processing if, as an effect of cold runner injection molding, gate residue  150  is left behind. In various embodiments, the gate may be located directly opposite an internal surface feature  140 . The housing  100  is transparent in  FIG. 9P  in order to show details such as internal surface feature  140 .  FIGS. 9Q-9R  illustrate examples of the molded housing  100  after subsequent processing. In various embodiments, a minor aperture may be opened directly opposite an internal surface feature  140 . In some embodiments, internal surface features may be configured to provide structural or mechanical support to housing features that are added in subsequent processing steps. 
     In accordance with various embodiments, as illustrated in  FIG. 10 , a housing of unitary construction may be formed in an injection molding process. In operation  1000  a process for molding a housing of unitary construction may be started. In operation  1005 , a major internal mold assembly may be obtained or provided. The major internal mold assembly may include providing a plurality of movable interior slides each having an extraction protrusion in a first position for forming an interior cavity of the housing. In operation  1010 , a major external mold assembly may be obtained or provided. The major external mold assembly may include providing a plurality of movable components in a first position for forming a major external surface of the housing. A cavity may be formed between the major internal mold assembly and the major external mold assembly. The cavity may be configured for injecting resin to form the housing of unitary construction. The major external mold assembly may mate with the extraction protrusion of each of the plurality of movable interior slides. In operation  1015 , resin may be injected in the cavity between the major internal mold assembly and the major external mold assembly. This injection may form a major internal surface and a major external surface, respectively. The formation of the surfaces forms the housing of unitary construction. In operation  1020 , a major aperture may be formed in the housing of unitary construction. The aperture may pass from the interior cavity through the interior surface and the exterior surface of the housing. The major aperture may be formed around the extraction protrusions of each of the movable slides. For example, the aperture formation may be located where the major external mold assembly mates with the extraction protrusion of each of the plurality of movable interior slides. This location may be proximal to the cavity formed between the major internal mold assembly and the major external mold assembly. In operation  1030 , a first moveable interior slide may be removed through the aperture formed in the housing of unitary construction. In operation  1040 , a second moveable interior slide may be moved within the formed housing of unitary construction toward the aperture and in operation  1050 , the second moveable interior slide may be removed through the aperture formed in the housing of unitary construction. In operation  1060 , the first movable exterior mold component may be removed. In operation  1070 , the housing of unitary construction may be removed from the tooling. Although presented in one particular sequence in  FIG. 10 , one of skill in the art will appreciate that the various procedures may be completed in any of a variety of orders. 
     In accordance with various embodiments, as illustrated in  FIG. 11 , an injection molding process which begins in operation  1800  may be utilized in forming a housing of unitary construction. In operation  1805 , an interior surface assembly may be provided. For example, the interior surface assembly similar to the interior mold assembly  200 . In operation  1810 , an aperture assembly may be provided. The aperture assembly may contour a major aperture of the housing of unitary construction. For example, the aperture assembly may be similar to aperture mold assembly  300 . In operation  1815 , an exterior surface assembly may be provided. 
     In operation  1820   a - c , an interior surface, interior surface features, an exterior surface, or an aperture surface may be molded. In an example, if the molding process is injection molding,  1820   a - c  may occur simultaneously as the mold material fills the available mold cavity space. In another example, the interior, exterior, or aperture surfaces may be molded in distinct steps. For example, multiple gates may provide mold material to different sectional volumes of the mold cavity. In operation  1825 , after molding, a first interior mold component may be removed through the molded aperture, such as the motion discussed in the various examples above see e.g.  9 A-B or  FIG. 5E . In various embodiments, this first interior mold component may be removed at ninety degrees. In various embodiments, the first interior mold component may be removed at an angle. In still further embodiments, a sequence of interior mold components may be removed in a repetition of operation  1825 . In operation  1830 , a second interior mold component remaining within the molded housing may be moved towards the aperture, such as the motion discussed in the various examples above, see e.g.  FIGS. 9C-D  or  FIG. 5F . In various embodiments, the second interior mold component&#39;s motion may cause other mold components to move. In still further embodiments, a sequence of interior mold components may be removed in a repetition of step  1830 . In operation  1835 , an exterior mold assembly may be removed. In various embodiments, the individual components of the exterior mold assembly may be removed sequentially. In other embodiments, the components may be removed contemporaneously. In operation  1840 , a fixture may be coupled to the formed mold, see e.g. the coupling illustrated in  FIGS. 9M-N . In some embodiments, the coupling may be a friction fit. In other embodiments, the fixture may actively adhere itself to the formed component with suction or some similar means. In operation  1845 , the fixture and formed mold may be removed together over the interior mold components remaining within the interior volume of the formed housing. In various embodiments, the fixture and formed mold are removed at an angle. Although presented sequentially in  FIG. 11 , one of skill in the art will appreciate that the various procedures may be completed in a variety of orders. 
     In accordance with various embodiments as illustrated in  FIG. 12 , a mold for formation of a housing of unitary construction may be disassembled. In operation  1900 , the process of disassembly may begin. In operation  1905 , the disassembly may include removing a first interior surface assembly component beyond an interior volume of a formed mold. In various embodiments, the first slide may be removed at an angle. In other embodiments, the first slide may be removed at ninety degrees. In still further embodiments, a sequence of interior mold components may be removed in a repetition of operation  1905 . In operation  1910 , a second interior surface assembly component still within the formed mold may be compressed. The compression may, for example, be caused by the motion of another component. In operation  1915 , a second interior surface assembly may be moved toward an aperture of the formed mold. In various embodiments, the second interior surface assembly may be made up of multiple individual slides, each of which may move together or independently toward the aperture of the formed mold. In still further embodiments, a sequence of interior mold components may be removed in a repetition of the previous processes. In operation  1920 , components of an exterior mold assembly may be removed. In various embodiments, the individual components of the exterior mold assembly may be removed sequentially. In other embodiments, the components may be removed contemporaneously. In operation  1925 , a fixture may be coupled to the formed mold, see e.g. the coupling illustrated in  FIGS. 9M-N . In various embodiments, the coupling may be a friction fit. In other embodiments, the fixture may actively adhere itself to the formed component with suction or some similar means. In operation  1930 , the fixture and formed mold may be removed together over the interior mold components remaining within the interior volume of the formed housing. In various embodiments, the fixture and formed mold are removed at an angle. 
     As used throughout this document in each of the embodiments, aspects, examples, lists and various descriptions of the subject matter contained herein, the word “or” is intended to be interpreted in its inclusive form (e.g. and/or) not in its exclusive form (e.g. only one of) unless explicitly modified to indicate only one item in a list is intended (e.g. only one of A, B, or C). For example, the phrase A, B, or C is intended to include any combination of the elements. The phrase can mean only A. The phrase can mean only B. The phrase can mean only C. The phrase can mean A and B. The phrase can mean A and C. The phrase can mean B and C. The phrase can mean A and B and C. This concept extends to any length of list (e.g. 1, 2, 3 . . . n) used herein. 
     Although the foregoing discussion has presented specific embodiments, the foregoing merely illustrates the principles of the invention. Persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the disclosure as various modifications and alterations to the described embodiments will be apparent to those skilled in the art, in view of the teachings herein. For example, the processing steps may be performed in another order, or in different combinations. It will thus be appreciated that those having skill in the art will be able to devise numerous systems, arrangements and methods which, although not explicitly shown or described herein, embody the principles of the disclosure and are thus within the spirit and scope of the present invention. From the above description and drawings, it will be understood by those of ordinary skill in the art that the particular embodiments shown and described are for purposes of illustration only, and references to details of particular embodiments are not intended to limit the scope of the present invention, as defined by the appended claims.

Metadata:
Filing Date: 20130926
Publication Date: 20170704
Grant Date: 20170704
Priority Date: 20130315
Inventors: VILLARREAL CESAR LOZANO
LANGLOIS RICHARD J.
KWAN ALEXANDER
KEANE CIARAN
DOLCI DOMINIC E.
GOH CHIEW-SIANG
BERG BRUCE E.
Assignee: APPLE INC
CPC Classifications: [{"code": "B29C45/2628", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R31/065", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/4421", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/0278", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/4421", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C45/2628", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/376", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C45/33", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/2628", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/4421", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/33", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K5/0278", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/33", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/4421", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R31/065", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/33", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/376", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C45/2628", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K5/0278", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/0278", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 51524503