Continuous molded plastic components or assemblies

A continuous strip of separable units containing spaced electrical or mechanical components comprising:

• (a) a consecutive series of injection-molded segments of moldable material,
• (b) each segment comprising a consecutive series of integrally connected but severable units comprised of first leading and second trailing end units and a plurality of middle units between the end units, said middle units each being of moldable material and separated along their length from each other,
• (c) except for end segments, one of the first and second end units of each segment having a portion overmolding a projecting portion of the other of the first and second end units of an adjacent segment whereby successive segments are integrally coupled by their respective overmolded and projecting portions of the first and second end units and with the projecting portion of the other of the first and second end units of each segment having had a hole or recessed portion filled with molded material of the overmolding portion of the one of the first and second end units of the adjacent segment, said projecting portion of the other end unit comprising a rearwardly projecting portion extending approximately in line with the strip,
• (d) the integrally coupled segments forming an elongated strip of molded units,
• (e) each of the units having a hole for receiving an electrical or mechanical component,
• (f) the projecting portion also having a hole for receiving an electrical or mechanical component and the overmolding portion allowing access by the electrical or mechanical component to the hole in the projecting portion,
• (g) a plurality of spaced approximately in-line electrical or mechanical components each mounted in one of the holes in the units including the hole in the projecting portion along substantially the length of said elongated strip, whereby a desired pitch distance between the mounted components is preserved and one or more individual units can be severed from the strip as desired.

A method of forming a continuous elongated injection-molded length of moldable material comprising a plurality of longitudinally spaced components having a desired pitch distance, comprising the steps:

• (a) providing a mold shaped to form one segment of moldable material, said one segment comprising a consecutive series of connected, integral units having a given thickness and comprised of first and second end units and a plurality of middle units between the end units, at least the second end unit forming a projecting portion approximately in line with the units, said projecting portion being provided with recessed areas,
• (b) introducing into the mold molten material and allowing same to cool to form a first segment of moldable material with the second end unit comprising the projecting portion with the recessed areas,
• (c) removing from the mold the first segment and reinserting the projecting portion of the first segment in the mold,
• (d) introducing into the mold molten material and allowing same to cool to form a second segment with first and second end units and middle units with the first end unit of the second segment overmolded with and at least partially encapsulating the projecting portion of the second end unit of the first segment and with the recessed areas in the projecting portion filled with molded material whereby the first and second segments are integrally coupled by their respective overmolded and projecting portions,
• (e) repeating step (c) with respect to the second segment and step (d) to form a third segment integrally coupled with the second segment, and so on, whereby successive segments can be formed and integrally coupled to form an elongated continuous strip of molded segments,
• (f) providing the components along the length of the strip spaced so as to preserve the desired pitch distance.

A method of forming a continuous elongated injection-molded strip of moldable material comprising a plurality of spaced approximately in-line components, comprising the steps:

• (a) providing a mold shaped to form one segment of moldable material, said one segment comprising a consecutive series of connected, integral units comprised of first and second end units and a plurality of middle units between the end units, at least the second end unit comprising a projecting portion approximately in line with the strip,
• (b) providing a core pin positioned to form a hole in the projecting portion,
• (c) introducing into the mold molten material and allowing same to cool to form a first segment of material with some of the middle units incorporating a hole and with the second end unit comprising the projecting portion containing a hole,
• (d) removing from the mold the first segment and reinserting the projecting portion of the second end unit of the first segment in the mold,
• (e) introducing into the mold molten material and allowing same to cool to form a second segment with first and second end units and middle units with some of the middle units incorporating a hole and with the first end unit of the second segment comprising a part overmolded with the projecting portion of the second end unit of the first segment and with the hole in the projecting portion filled with a crossbar of molded material whereby the first and second segments are integrally coupled by the overmolded projecting portion,
• (f) repeating step (d) with respect to the second segment and step (e) to form a third segment integrally coupled with the second segment, and so on, whereby successive segments can be formed and integrally coupled to form an elongated strip of moldable material.

A method of forming a continuous elongated injection-molded strip of moldable material comprising a plurality of spaced approximately in-line components, comprising the steps:

• (a) providing a mold shaped to form one segment of moldable material, said one segment comprising a consecutive series of connected, integral, units comprised of first and second end units and a plurality of middle units between the end units, at least the second end unit comprising a rearwardly projecting portion extending generally laterally of and approximately in line with the strip, said projecting portion having a hole or recessed area,
• (b) introducing into the mold molten material and allowing same to cool to form a first segment of moldable material and with the second end unit comprising the projecting portion,
• (c) removing from the mold the first segment and reinserting the projecting portion of the second end unit of the first segment in the mold,
• (d) introducing into the mold molten material and allowing same to cool to form a second segment with first and second end units and middle units and with the first end unit of the second segment comprising a part overmolded with and at least partially encapsulating the projecting portion of the second end unit of the first segment and with the hole or recessed portion in the projecting portion filled with molded plastic whereby the first and second segments are integrally coupled by the overmolded projecting portion,
• (e) repeating step (c) with respect to the second segment and step (d) to form a third segment integrally coupled with the second segment, and so on, whereby successive segments can be formed and integrally coupled to form an elongated strip of moldable material comprising plural components.

A method of forming a continuous elongated injection-molded length of moldable material comprising a plurality of longitudinally spaced components, comprising the steps:

• (a) providing a mold shaped to form one segment of moldable material, said one segment comprising a consecutive series of connected, integral units having a given thickness and comprised of first and second end units and a plurality of middle units between the end units, at least the second end unit forming a projecting portion approximately in line with the units, said projecting portion comprising a laterally extending strip of material thinner than the given thickness and having an outer edge and provided with recessed areas between the outer edge and the adjacent second end unit,
• (b) introducing into the mold molten material and allowing same to cool to form a first segment of moldable material with the second end unit comprising the projecting portion with recessed areas between the outer edge and the adjacent second end unit,
• (c) removing from the mold the first segment and reinserting the projecting portion of the first segment in the mold,
• (d) introducing into the mold molten material and allowing same to cool to form a second segment with first and second end units and middle units with the first end unit of the second segment overmolded with and at least partially encapsulating the projecting portion of the second end unit of the first segment and with the recessed areas in the projecting portion filled with molded material whereby the first and second segments are integrally coupled by their respective second and overmolded projecting portion,
• (e) repeating step (c) with respect to the second segment and step (d) to form a third segment integrally coupled with the second segment, and so on, whereby successive segments can be formed and integrally coupled to form an elongated length of molded components.

A continuous strip of separable pin headers comprising:

• a consecutive series of injection-molded segments of a moldable material, the segments including leading and trailing segments;
• each segment comprising a consecutive series of integrally connected but severable header units formed of the moldable material and having a leading end and a trailing end, and including at least one partially formed trailing end unit;
• at least one unit at the leading end of each trailing segment having a portion overmolding at least one partially formed trailing end unit of an adjacent leading segment whereby successive segments are integrally coupled by their respective overmolded portions of at least one trailing end unit by at least one leading end unit of an adjacent segment, and said at least one trailing end unit of each segment having a recessed portion filled with the molded material of the overmolded portion of the at least one leading end unit of the adjacent segment;
• the integrally coupled segments forming an elongated continuous strip of molded header units, said units each having at least one pin receiving hole and being separated along their length from each other, and
• a plurality of spaced approximately in-line electrically-conductive pin components provided in said pin receiving holes in and along substantially the length of said elongated strip, whereby one or more individual header units containing pins can be severed from the strip as desired.

A continuous strip of separable pin headers comprising:

• a consecutive series of injection-molded segments of a moldable material, the segments including leading and trailing in-line end portions;
• each segment comprising a consecutive series of at least three integrally connected but severable header units formed of the moldable material and having a partially formed trailing end portion;
• an end portion at the leading end of each trailing segment having a portion overmolding the partially formed trailing end portion of an adjacent leading segment whereby successive segments are integrally coupled by their respective in-line overmolded portions, and said trailing end portion of each segment having a recessed portion filled with the molded material of the overmolded portion of the leading end portion of the adjacent segment;
• the integrally coupled segments forming an elongated strip of in-line molded header units, said units each having at least one pin-receiving hole and being separated along their length from each other;
• and
• a plurality of spaced approximately in-line electrically-conductive pin components provided in said pin-receiving holes in and along substantially the length of said elongated strip, whereby one or more individual header units containing pins can be severed from the strip as desired.