A method for producing a conductive member in which an insulating film is interposed between two metal plates includes: a first molding step for forming an intermediate product in which a solidified, insulating first resin covers the insulating film, such that the insulating film is at least partially exposed; and a second molding step for covering sandwiching parts of the two metal plates with an insulating second resin in a state where at least a portion of the exposed part of the insulating film of the intermediate product is sandwiched between the two metal plates.

A roof rail for a vehicle is provided that is made of only one piece and is solid across its length. The roof rail may be made using a co-injection molding process, a two-shot injection molding process or an extrusion molding process.

Disclosed herein are methods and systems for co-extruding multiple polymeric material flow streams into a mold cavity to produce a molded plastic article. At least one interior core stream of a first polymeric material is surrounded by inner and outer streams of at least one other polymeric material. The interior core stream serves as an interior layer of a resultant molded plastic article while the inner and outer streams serve as inner and outer layers, respectively, of the resultant plastic article. The interior core stream is selectively directed to flow into or past a downstream branch channel in a mold cavity. The downstream branch channel branches from a primary channel in the mold cavity at a branch junction. The branch channel defines a protrusion portion of the resultant molded plastic article. The leading edge of the interior core stream is selectively controlled in the branch channel to position the leading edge at or near to the terminal end of the branch channel without having the leading edge of the interior core stream breakthrough a flow-front of the inner and outer streams. The resultant molded plastic article includes an interior layer formed of the first polymeric material that extends into, through and to a distal end of the protrusion while still being encased by inner and outer layers formed from the inner and outer flow streams.

A method for the production of an injection-molded part including casting an injection-molding material at least two injection-molding stations by at least two injection-molding processes. A pre-molded part, produced in one of the at least two injection-molding processes, is cooled in a cooling station between the at least two injection-molding processes.

Methods and systems for co-extruding multiple polymeric material flow streams into a mold having a plurality of cavities to produce a plurality of multi-layer polymeric articles each having a consistent coverage of an interior core layer are disclosed herein. In an example method, a flow rate of a first skin material into a cavity is individually controlled for each cavity before initiation of co-injection of a second core material into the cavity, which may address inconsistent interior core layer coverage for articles from different cavities.

The multistep injection molding device is for manufacturing thick lenses for use with an illumination apparatus. The injection molding device includes two sets of mold core inserts forming mold cavities when the injection molding device is in a closed position. The lens core part is formed in a first injection shot station. The molded lens core part is then moved to a post-molding cooling station in which it is further cooled inside a corresponding mold cavity. Two outer lens parts are formed sequentially over the lens core part in second and third injection shot stations. A method of manufacturing a thick lens is also disclosed.

A method, for manufacturing an electronic assembly, such as an antenna or a capacitive sensing device or a coupled inductor, comprising at least a first electrically conductive element and a second electrically conductive element is presented. The method comprises obtaining said electrically conductive elements, such as patch elements, arranging said electrically conductive elements, such as inside of a cavity defined by a mold structure, at a pre-defined distance from each other for establishing an electromagnetic coupling between said electrically conductive elements, and molding, such as injection molding, a molding material layer at least between said electrically conductive elements, wherein the molding material layer has a thickness between said electrically conductive elements defined by the pre-defined distance. In addition, electronic assemblies, antennas, capacitive sensing devices and coupled inductors are presented.

Systems and methods for lighting system lens heating are described. The systems and methods include a substantially clear thermoplastic substrate; and a conductive ink or film circuit on the thermoplastic substrate.

A co-injection molding apparatus may mold an injection product that includes a skin layer forming an outer surface by a first material and a core layer surrounded by the skin layer and having an interior formed by a second material. The co-injection molding apparatus may include an injection mold configured to form an injection space to be injection molded by the first material and the second material, a first injector configured to inject the first material, a second injector configured to inject the second material different from the first material and positioned between the first injector and the injection mold, and a runner configured to connect the first injector, the second injector, and the injection mold.

An injection molding method of a part for vehicle interiors includes arranging a mold having a first injection chamber defining in negative a base of the part. Thermoplastic material is injected into the first chamber and the base is extracted from the first chamber and placed in a second injection chamber. A lining film is inserted in the second chamber and deforming it to arrange the film on an outer surface thereof, adhering to an esthetic wall of the second chamber opposite a functional wall. An intermediate plastic layer is injected in a gap between an inner wall of the base facing the lining film, and an inner surface of the lining film opposite the outer surface to create a single sandwich structure. The intermediate layer is between the lining film and the base, has lower hardness than the base and forms a yielding padding for the lining film.