PLASTIC OVERMOLDING OF ALUMINUM EXTRUSIONS

摘要

A plastic overmold aluminum extrusion including at least one plastic overmold (14) and aluminum extrusion (12). The aluminum extrusion (12) is formed with sufficient cross sectional properties and features such as an internal web (16) to help prevent undesirable collapses under injection or compression molding pressures. This improves part geometry and strength while minimizing weight. A plurality of protrusions (32) and/or local deformations on an outer wall of the extrusion can be used to create strong mechanical interface to the plastic. Localized deformations can result from a combination of the applied plastic pressure under injection or compression molding pressures and the proximity of outer gaps of the internal web structure. A process of making the plastic overmold aluminum extrusion includes inserting at least one aluminum extrusion into a mold without mandrels and delivering plastic forming the plastic overmold.