Insert molding

Abstract

A method and apparatus involve positioning an insert within a cavity of a mold, heating an insert wall within the cavity of the mold, and casting a molten metal into the cavity adjacent the insert. A surface of the insert absorbs heat from the molten metal to melt and fuse to the molten metal.

1 . A method comprising:
 positioning an insert within a cavity of a mold;   heating the insert wall within the cavity of the mold; and   casting a molten metal into the cavity adjacent the insert, wherein a surface of the insert absorbs heat from the molten metal to melt and fuse to the molten metal.   
   
   
       2 . The method of  claim 1  further comprising providing an inert gas adjacent the surface during heating of the insert. 
   
   
       3 . The method of  claim 2 , wherein the inert gas is provided through a port and wherein the method further comprises moving an ejection pin from a first position closing the port to a second position opening the port. 
   
   
       4 . The method of  claim 1 , wherein the surface of the insert and the molten metal are from a same family of alloys. 
   
   
       5 . The method of  claim 1  further comprising applying electrical current to the insert to heat the insert within the mold cavity. 
   
   
       6 . The method of  claim 5  further comprising providing an inert gas adjacent the surface during heating of the insert. 
   
   
       7 . The method of  claim 5  further comprising an electrically insulating the insert from the mold. 
   
   
       8 . The method of  claim 5  further comprising terminating the application of electrical current to the insert immediately preceding casting of the molten metal into the cavity. 
   
   
       9 . The method of  claim 1  further comprising applying a release layer to the mold. 
   
   
       10 . The method of  claim 9 , wherein the release layer is configured to be attracted to the mold due to an electrical charge applied to the mold. 
   
   
       11 . An insert molding system comprising:
 a mold having a cavity configured to receive an insert;   an insert heating system configured to heat at least a surface of the insert while the insert is within the cavity to a temperature below a melting temperature of the surface; and   a casting system configured to cast a molten metal into the cavity adjacent the surface of the insert, the molten metal supplying heat to the surface of the insert to raise a temperature of the surface to above the melting temperature of the surface.   
   
   
       12 . The system of  claim 11 , wherein the insert heating system comprises a electrical heating system configured to apply an electrical current across the insert. 
   
   
       13 . The system of  claim 12  further comprising at least one electrically insulating member configured to extend between the insert and the mold when the insert is within the mold. 
   
   
       14 . The system of  claim 13 , wherein the at least one electrically insulating member comprises an electrically non-conductive mold component. 
   
   
       15 . The system of  claim 13 , wherein the at least one electrically insulating member includes one or more ceramic materials. 
   
   
       16 . The system of  claim 12  further comprising a gas introduction system configured to provide an inert gas adjacent to the surface of the insert within the cavity during heating of the insert. 
   
   
       17 . The system of  claim 16 , wherein the gas introduction system provides the inert gas through a shot sleeve of the casting system. 
   
   
       18 . The system of  claim 12  further comprising a controller configured to generate control signals directing the electrical heating system to terminate the application electric current across the insert prior to the fluid material from the casting system contacting the surface of the insert. 
   
   
       19 . The system of  claim 11  further comprising a gas introduction system configured to provide an inert gas adjacent to the surface of the insert within the cavity during heating of the insert. 
   
   
       20 . The system of  claim 19 , wherein the gas introduction system introduces the inert gas through a shot sleeve of the casting system.