The present invention includes systems and methods for insert-molding. In some embodiments, a hook can be formed in a metal part by passing die-steel of a die-cast mold through the metal part during a die-casting process. This may, however, result in a hole in the metal part that is beneath the hook
The present invention includes systems and methods for insert-molding. In some embodiments, a hook can be formed in a metal part by passing die-steel of a die-cast mold through the metal part during a die-casting process. This may, however, result in a hole in the metal part that is beneath the hook area. When plastic material is insert-molded over the metal part, the plastic material may flow through the hole and into the metal part. Accordingly, in some embodiments the plastic material can be prevented from flowing through the hole during the insert-molding. As one example, a tape material can be coupled over the hole. As another example, a wedge can be press-fit into the hole. As yet another example, a plug can be inserted into the hole.
대표청구항▼
1. A method comprising: injecting molten metal into a die-cast mold;allowing the molten metal to harden to form a metal piece;passing die steel of the die-cast mold through the molten metal during the injecting;removing the metal piece from the die-cast mold, wherein the metal piece comprises a hook
1. A method comprising: injecting molten metal into a die-cast mold;allowing the molten metal to harden to form a metal piece;passing die steel of the die-cast mold through the molten metal during the injecting;removing the metal piece from the die-cast mold, wherein the metal piece comprises a hook;press-fitting a wedge into a hole passing through the metal piece, wherein the hole is formed as a result of the passing of the die steel; andinsert-molding a plastic material onto at least a portion of the metal piece, wherein the wedge prevents the plastic material from passing through the hole during the insert-molding and a gap in the wedge allows an external part that is coupled over the hook to move at least one of towards the hole and away from the hole. 2. The method of claim 1, wherein the hook is formed via the passing of the die steel through the molten metal during the injecting. 3. A method comprising: injecting molten metal into a die-cast mold;allowing the molten metal to harden to form a metal piece, wherein the metal piece comprises a hole passing through it and wherein the hole was formed by passing die steel of the die-cast mold through the molten metal during the injecting;removing the metal piece from the die-cast mold;press-fitting a wedge into the hole;insert-molding a plastic material onto at least a portion of the metal piece, wherein the wedge prevents the plastic material from passing through the hole during the insert-molding, and wherein the metal piece further comprises a hook formed via the passing of the die steel through the molten metal during the injecting; andcoupling a moveable part over the hook, and wherein the wedge comprises a gap providing space for the moveable part to shift position. 4. A method comprising: injecting molten metal into a die-cast mold;allowing the molten metal to harden to form a metal piece, wherein the metal piece comprises a hole passing through it and wherein the hole was formed by passing die steel of the die-cast mold through the molten metal during the injecting;removing the metal piece from the die-cast mold;press-fitting a wedge into the hole; andinsert-molding a plastic material onto at least a portion of the metal piece, wherein the wedge prevents the plastic material from passing through the hole during the insert-molding, and wherein the wedge comprises zinc. 5. A method comprising: injecting molten metal into a die-cast mold;allowing the molten metal to harden to form a metal piece, wherein the metal piece comprises a hole passing through it and wherein the hole was formed by passing die steel of the die-cast mold through the molten metal during the injecting;removing the metal piece from the die-cast mold;press-fitting a wedge into the hole; andinsert-molding a plastic material onto at least a portion of the metal piece, wherein the wedge prevents the plastic material from passing through the hole during the insert-molding, and wherein the wedge comprises a draft angle of two degrees. 6. The method of claim 1, wherein the metal piece is formed from a first metal and the wedge is formed from a second metal, and wherein the second metal is softer than the first metal. 7. A method comprising: die-casting a metal piece, wherein the metal piece includes a hole associated with a hook feature of the metal piece, and wherein the hole extends from a bottom surface of the metal piece to a top surface of the metal piece;press-fitting a wedge having a gap into the hole such that the wedge occupies only a portion of the hole; andinsert-molding a plastic material onto at least a portion of the metal piece, wherein the wedge prevents the plastic material from passing through the hole during the insert-molding. 8. The method of claim 7, wherein the hook feature is positioned above the hole. 9. The method of claim 7, wherein press-fitting the wedge into the hole comprises: press-fitting the wedge from the bottom surface of the metal piece. 10. The method of claim 7, wherein press-fitting the wedge into the hole comprises: press-fitting the wedge from the top surface of the metal piece. 11. The method of claim 7, wherein the plastic material comprises at least one of a thermoplastic and a thermosetting plastic. 12. The method of claim 7, wherein insert-molding the plastic material further comprises: forming a protective barrier on the metal piece by insert-molding the plastic material onto the at least a portion of the metal piece. 13. A method comprising: die-casting a metal piece, wherein the metal piece includes a hole extending from a bottom surface of the metal piece to a top surface of the metal piece;press-fitting a wedge into the hole; andinsert-molding a plastic material onto at least a portion of the metal piece, wherein the wedge prevents the plastic material from passing through the hole during the insert-molding, and wherein the metal piece comprises a volume less than 9 millimeters cubed. 14. The method of claim 7, wherein the die-casting comprises: injecting a molten metal in a die-cast mold;allowing the molten metal to harden into the metal piece; andremoving the metal piece from the die-cast mold after the molten metal has hardened, wherein the hole is formed by passing die steel of the die-cast mold through the molten metal during the injecting of molten metal. 15. The method of claim 14, wherein the die-casting further comprises: forming the hook feature in the metal piece via the passing of the die steel through the molten metal during the injecting of molten metal. 16. A method comprising: injecting molten metal into a die-cast mold;allowing the molten metal to harden to form a metal piece, wherein the metal piece comprises at least one hook;passing die steel of the die-cast mold through the molten metal during the injecting;removing the metal piece from the die-cast mold;sealing a hole passing through the metal piece, wherein the hole is formed as a result of the passing of the die steel; andinsert-molding a plastic material onto at least a portion of the metal piece, wherein the sealing prevents the plastic material from passing through the hole during the insert-molding and a gap in the sealing allows an external component that is coupled over the at least one hook to move within an area between the hook and the hole. 17. The method of claim 16, wherein the sealing includes sealing the hole with a wedge. 18. The method of claim 16, wherein the sealing includes sealing the hole with a plug.
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