Methods and apparatus for applying internal features or complex mechanical structures to a surface of a metal part are disclosed. According to one aspect of the present invention, a method for creating an assembly that includes a substrate and a molded piece involves obtaining the substrate, and forming at least one binding feature on a surface of the substrate. The method also includes molding on a surface of the binding feature and the surface of the substrate. Molding on the surface of the binding feature and the surface of the substrate mechanically binds the molded piece to the substrate.

A dispenser part includes a first injection molded plastic component part with an associated first mating surface along a first edge; a second injection molded plastic component part having an associated second mating surface; a seam formed by the first mating surface and the second mating surface during injection moulding for joining the first component part and the second component part to define a dispenser part. A transverse cross section of the seam includes at least one step and at least one contact surface intermediate an inner and an outer surface of the dispenser part.

An injection molding method includes providing a molding device including a first mold, a second mold over the first mold and a first mold cavity defined by the first mold and the second mold; injecting a first material into the first mold cavity; forming a first layer from the first material; replacing the second mold by a third mold; injecting a second material into a second mold cavity defined by the first mold and the third mold; and forming a second layer from the second material disposed over the first layer, wherein the first material is different from the second material.

A dispenser part, includes a first injection moulded plastic component part with an associated first mating surface along a first edge; a second injection moulded plastic component part having an associated second mating surface; a seam formed by the first mating surface and the second mating surface during injection moulding for joining the first component part and the second component part to define a dispenser part. A transverse cross section of the seam includes at least one step and at least one contact surface intermediate an inner and an outer surface of the dispenser part.

An actuator cap (1;50) for a fluid spray dispenser comprises a second body part (2) and a first body part (3). The first body part (3) is adapted for connection to a container for the fluid to be dispensed and incorporates a spray channel arrangement (4). The second body part (2) incorporates an actuator button (5) and is rotatable with respect to the first body part (3) from a first position in which the actuator button (5) is non-elevated into a second position in which the actuator button (5) is elevated and capable of depression to cause depression of a part (16) of the spray channel arrangement (4). The actuator button (4) defines a first cam profile (20) along which a first cam follower (22) defined by the first body part (3) travels to cause elevation or retraction of the actuator button (5) when the second body part (3) is rotated. The actuator button (5) also defines a second cam profile (23) that bears against said part (21) of the spray channel arrangement (4) such that when the actuator button (5) is in its elevated position and depressed the actuator button (5) depresses said second cam profile (23) and in turn depresses said part (21) of the spray channel arrangement (4) relative to the first body part (3) to dispense fluid from the container when in use. Preferably, the first and second body parts (3, 2) are individual, integrally moulded components that are snap-fitted together to assemble the actuator cap (1; 50).

A method of forming a cap assembly comprises injection molding a cap in a first shot from a first polymeric material, wherein the cap has an opening at one end defined by a perimeter. Injection molding a tamper band in a second shot from a second polymeric material such that the tamper band is monolithically attached to the perimeter of the cap. The first polymeric material and the second polymeric material comprise dissimilar resins and the tamper band is configured to sever from the cap with no burrs remaining on the perimeter of the cap.

A dual-molded silicone-polyamide composite article including a first molded piece that comprises a blend of polyamide and an ethylene-vinyl alcohol copolymer and a second molded piece that comprises a thermoset, hydrosilylation-cure silicone polymer. A portion of a surface of the second molded piece is autogenously bonded to a portion of a surface of the first molded piece.

The present disclosure relates to a surface-modifiable injection-molded body comprising a thermoplastic polymer matrix and second polymer material at least in parts, in which the polymer matrix and the second polymer material have different weight average molecular weights and polarities, and the second polymer material is an adhesive. The present disclosure also relates to a method for its production.

An outer shell for a dispenser and a method for making same are provided, the outer shell including first and second injection molded plastic component parts. The first and second component parts each include an outer surface and an inner surface, with the first component part having a first mating surface directed to the outer surface of the first component part and the second component part having a second mating surface directed to an inner surface of the second component part. The first and second component parts are joined to each other along a seam by mating the first mating surface and the second mating surface during injection moulding. A plurality of recesses is formed in the inner surface of the first component part along the seam and/or on a gate protrusion extending away from a free end of the first mating surface of the first component part.

A method of forming a molded polymer part having a screw boss includes positioning a screw boss insert on a pin of a mold tool. The screw boss insert may contact guide surfaces of the mold tool. During molding, polymer material flows along the screw boss insert while the screw boss insert is positioned on the pin. The polymer material may bond to the screw boss insert. The screw boss insert may include one or more geometric features that prevent rotation and/or axial movement of the screw boss insert relative to the surrounding polymer material.