# US 8,784,715 B2 · Structure of parts made from plural composite pieces and method of building those parts

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- Number: US 8,784,715 B2
- Document ID: US8784715B2
- Status: Granted
- Kind: B2
- Application number: 12/616,826
- Filed: 2009-11-12
- Published: 2010-03-04
- Granted: 2014-07-22
- Earliest claimed: 2004-07-02
- Assignees: Hitachi, Ltd.
- Applicants: Katsuhide Oohashi; Shigeo Amagi; Osamu Miyo
- Inventors: Katsuhide Oohashi; Shigeo Amagi; Osamu Miyo
- Web page: https://patentgrep.com/patent/US8784715B2

## CPC

- H05K 5/0069: {having connector relating features for connecting the connector pins with the PCB or for mounting the connector body with the housing}
- B29C 45/14639: {for obtaining an insulating effect, e.g. for electrical components}
- B29C 45/1671: {with an insert}
- B29C 70/72: Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components {(B29C70/742 takes precedence)}
- H01R 43/24: Assembling by moulding on contact members
- B29C 71/0063: {for changing crystallisation}
- B29C 2045/14893: {Preventing defects relating to shrinkage of inserts or coating material}
- B29K 2995/0041: Crystalline
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

## Abstract

A pre-molded part is formed by pre-molding an insert with a pre-molded member, and then the pre-molded part is inserted into an over-molded member composed of thermo plastic resin. After applying a heat treatment with a temperature lower than a crystalline melting point of the pre-molded part to the pre-molded part surrounding the insert, a firm contact between the insert and the resin surrounding the insert without a gap at the interface between those parts is obtained.

## Claims

### Claim 1

A production method of a composite molded part comprising:
providing a pre-molded member consisting essentially of thermoplastic resin having crystallinity,
subsequently forming at least one pre-molded part by pre-molding at least one insert member consisting essentially of metal, ceramic, resin, or a combination of those materials with the pre-molded member,
applying heat treatment to a surrounding pre-molded member of said pre-molded part at a temperature of from 130° C. to 170° C. lower than a crystalline melting point of said pre-molded part of from 220° C. to 270° C. for about one hour, and then applying an insert molding process to an over-molding member to insert said pre-molded part, which has been cooled, solidified, and molded, into the over-molding member, and
over-molding said at least one pre-molded part with an over-molded member consisting essentially of thermoplastic resin to form the composite molded part.

### Claim 2 (depends on 1)

The production method of claim 1, wherein said at least one insert member is at least one metallic terminal to be used for electrical connection.

### Claim 3 (depends on 1)

The production method of claim 1, wherein said pre-molded part includes plural insert members, and the pre-molded part is inserted and molded together with said over-molded part.

### Claim 4 (depends on 1)

The production method of claim 1, wherein said pre-molded part includes plural insert members, and said at least one pre-molded part is one of plural pre-molded parts that are overlapped, inserted, and molded together with said over-molded member.

### Claim 5 (depends on 1)

The production method of claim 1, wherein said pre-molded member and said over-molded member consist essentially of the same filled resin.

### Claim 6 (depends on 5)

The production method of claim 5, wherein an amount of filler in said pre-molded part is equal to an amount of filler in said over-molded member.

### Claim 7 (depends on 5)

The production method of claim 5, wherein said pre-molded member consists essentially of a resin with a filler fraction higher than that of said over-molded member.

### Claim 8 (depends on 1)

The production method of composite molding part according to claim 1, wherein both said pre-molded member and said over-molded member consist essentially of a resin filled with filler, and said pre-molded member consists essentially of a resin with a crystalline melting point higher than that of said over-molded member.

### Claim 9 (depends on 1)

The production method of composite molding part according to claim 1, wherein said pre-molded member and said over-molded member consist essentially of a filled resin, and said pre-molded member consists essentially of a resin with a crystalline melting point lower than that of said over-molded member.

### Claim 10 (depends on 1)

An electronic part formed by the production method according to claim 1, wherein a gap that remains at an interface between said at least one insert member and said pre-molded member after applying said heat treatment is narrower than a gap generated at an interface between said pre-molded part and said over-molded member after forming the composite molded part.