Injection moulding of functional cavities

1. A process of injection moulding a part with a functional cavity including the steps of;

providing a mould assembly comprising at least a first mould portion and a second mould portion which when joined together define a cavity for moulding the part, at least one of the first and second mould portions having an opening therein for allowing injection of a mouldable material into the cavity, a first recess in at least one of the first and second portions, the first recess being to receive a first hollow tubular insert intended to be placed in the mould assembly before the injection of a mouldable material into the cavity and to remain in the part after moulding, a second recess spaced apart from the first recess in at least one of the first and second portions, the second recess being to receive a second hollow tubular insert intended to be placed in the mould assembly before the injection of a mouldable material into the cavity and to remain in the part after moulding and a gas supply arrangement to supply pressurised gas to the first and second hollow tubular inserts during the injection process;

mounting a first hollow tubular insert into the first recess in the mould assembly;

mounting a second hollow tubular insert into the second recess in the mould assembly;

injecting a mouldable material through the opening into the cavity;

injecting a gas under pressure through the first and second hollow tubular inserts into the cavity; and

allowing the mouldable material to cool before opening the mould portions to release the moulded part with the first and second hollow tubular inserts retained in the moulded part and opening into the functional cavity;

whereby to allow fluid connection between the first hollow tubular insert and the second hollow tubular insert via the functional cavity.

2. A process as in claim 1 wherein the step of injecting mouldable material into the cavity comprises injection of a less than a complete volume of mouldable material to fill the cavity.

3. A process as in claim 1 wherein the volume of injected material, the time of injection and the pressure of injection and the volume, pressure, temperature and timing of gas injection are selected to give desirable properties and dimensions to the finished product and the functional cavity.

4. A process as in claim 1 wherein the mould assembly further includes a further cavity with a duct extending from the cavity to the further cavity and wherein the step of injecting mouldable material into the cavity comprises injection of a full shot of mouldable material into the mould and then when gas is injected into the mould through the hollow tubular insert, excess mouldable material is passed through the duct from the main cavity Into the further cavity.

5. A process as in claim 1 wherein the step of injecting mouldable material into the cavity includes the step of injecting a full shot of mouldable material and upon injection of the gas, excess mouldable material passing back through the opening back into an injection machine.

6. A process as in claim 1 further including the step of cooling the mould before injection of the gas, so to form a skin on the outer surface of the moulded part.

7. A process as in claim 1 further including a step of moulding a hard mouldable material onto part of the insert to form a coating around the part of the insert before placing the insert into the recess in the mould assembly.

8. A process as in claim 1 wherein the pressurised gas is air or dry nitrogen.