US 10,201,105 B2 · Combination injection molding and hydroforming

Abstract

Manufacturing methods that combine molding processes and shaping processes are described. The systems and methods described can be used to form composite parts using a single manufacturing process. In some embodiments, the methods involve positioning a workpiece within a mold cavity, then injecting a moldable material within the cavity at pressures sufficient to deform the workpiece such that features, such as protrusions or cavities, are formed within the workpiece. The resultant composite part includes the workpiece molded to a molded material. In some embodiments, the workpiece is a layer of metal material and the molded material is a structurally rigid plastic material, such that the composite part is a structurally rigid plastic with a metal coating. In some embodiments, multiple workpieces are molded within a composite part.

Claims20

Dependent claims

A method of forming a composite part, the method comprising:

positioning a workpiece within a mold cavity of a mold;
closing a valve within the mold cavity to at least partially define an enclosed portion of the mold cavity, the enclosed portion being less than an entirety of the mold cavity;
while the valve is closed, injecting a first amount of a moldable material into the enclosed portion of the mold cavity, thereby filling the enclosed portion and deforming a portion of the workpiece against a wall of the mold;
opening the valve;
while the valve is open, injecting a second amount of the moldable material into the mold cavity;
and
hardening the first amount and the second amount of the moldable material, thereby bonding the moldable material to the workpiece.

4 more elements

Dependencies are inferred from the claim text.

Combination injection molding and hydroforming

Life of this patent

Combination injection molding and hydroforming

Life of this patent

Abstract

Claims20