Housing with functional overmold

Abstract

An article having a first structure and a second structure. The first structure includes a structural portion and an overmold portion, which is formed from a resilient material and molded onto the structural portion. The overmold portion is configured to perform an auxiliary function, such as creating a seal portion that is configured to sealing engage the second structure, an isolator portion that is configured to contact the second structure and dampen vibrations that are transmitted thereto and/or an auxiliary gripping surface.

1 . An article comprising a housing structure and a secondary structure that are fixedly but removably coupled to one another, one of the housing structure and the secondary structure having a structural portion and an overmold portion that is formed from a resilient material and molded onto at least a portion of the structural portion such that the overmold portion is permanently and fixedly coupled to the structural portion, the overmold portion defining a seal portion that is configured to engage the other one of the housing structure and the secondary structure to form a seal between the structural portion and the other one of the housing structure and the secondary structure when the housing structure and the secondary structure are coupled to one another.  
   
   
       2 . The article of  claim 1 , wherein the resilient material is a thermoplastic.  
   
   
       3 . The article of  claim 2 , wherein the thermoplastic is a thermoplastic elastomer.  
   
   
       4 . The article of  claim 1 , wherein the one of the housing structure and the secondary structure is an end cap.  
   
   
       5 . The article of  claim 1 , wherein the overmold portion further includes a bumper member that is coupled to an exterior surface of the structural portion, the bumper member being configured to abut the other one of the housing structure and the secondary structure to limit movement of the other one of the housing structure and the secondary structure relative to the structural portion in a predetermined direction.  
   
   
       6 . The article of  claim 5 , wherein the bumper member is raised from the exterior surface of the molded portion but otherwise conforms to the shape of the structural portion in an area in which the bumper member and the other one of the housing structure and the secondary structure abut.  
   
   
       7 . The article of  claim 6 , wherein the overmold portion includes a linking member that couples the seal portion to the bumper member.  
   
   
       8 . The article of  claim 1 , wherein the article is a power tool.  
   
   
       9 . The article of  claim 8 , wherein the power tool is a drill.  
   
   
       10 . An article comprising a first structure and a second structure, at least one of the first and second structures having a structural portion and an overmold portion that is formed from a resilient material and at least partially molded onto the structural portion so as to be substantially permanently fixedly coupled thereto, the overmold portion defining an isolator portion that is configured to contact the other one of the first and second structures and dampen vibrations that are transmitted between the structural portion and the other one of the first and second structures.  
   
   
       11 . The article of  claim 10 , wherein the first structure is an end cap shell and the second structure is a motor.  
   
   
       12 . The article of  claim 10 , wherein the overmold portion also retains the other one of the first and second structures in a predetermined location relative to the structural portion.  
   
   
       13 . The article of  claim 10 , wherein the resilient material is a thermoplastic.  
   
   
       14 . The article of  claim 13 , wherein the thermoplastic is a thermoplastic elastomer.  
   
   
       15 . The article of  claim 10 , wherein the overmold portion further includes a bumper member that is coupled to an exterior surface of the structural portion, the bumper member being configured to abut the other one of the first and second structures to limit movement of the other one of the first and second structures relative to the structural portion in a predetermined direction.  
   
   
       16 . The article of  claim 15 , wherein the overmold portion includes a linking member that couples the isolator portion to the bumper member.  
   
   
       17 . The article of  claim 15 , wherein the bumper member is raised from the exterior surface of the structural portion but otherwise conforms to the shape of the structural portion in an area in which the bumper member and the other one of the first and second structures abut.  
   
   
       18 . The article of  claim 10 , wherein the article is a power tool.  
   
   
       19 . The article of  claim 18 , wherein the power tool is a drill.  
   
   
       20 . An article comprising: 
 a first structure;    a second structure, the second structure including a structural portion and an overmold portion that is overmolded onto the structural portion, the overmold portion resiliently deflecting to accommodate the first structure when the first and second structures are coupled to one another.    
   
   
       21 . A method comprising: 
 providing a first structure;    forming an overmold onto the first structure;    coupling a second structure to the first structure such that the overmold resiliently deflects to accommodate the second structure.    
   
   
       22 . A method comprising: 
 providing a first structure;    forming an overmold onto the first structure;    coupling a second structure to the first structure such that the overmold sealingly engages the second structure to thereby form a seal between the first and second structures.