Method of forming plastic part having hidden thin walled section

1. A method of forming a thin walled section in an injection molded plastic part comprising:

providing a mold having a first mold half, a second mold half, and a slide, wherein the first mold half, the second mold half, and the slide define a mold cavity when assembled and the slide includes a double angled step that defines a thin walled section of the plastic part, the slide being movable between a retracted position wherein the double angled step that defines the thin walled section partially retracted from the mold cavity and an engaged position wherein the double angled step that defines the thin walled section is in position to define the final shape of the plastic part;

injecting molten plastic into the mold cavity with the slide in the retracted position;

moving the slide to the engaged position such that the double angled step forms a gradual transition to a thinnest part of the thin walled section;

allowing the molten plastic to cool;

opening the mold halves and removing the plastic part; and

wherein each half of the double angled step is comprised of a first surface that defines a first angle with respect to the slide movement direction and a second surface that defines a second angle with respect to the slide movement direction, the second angle being greater than the first angle but less than ninety degrees, one end of each of the first surfaces defining the thinnest part of the thin walled section, an opposite end of each of the first surfaces being adjacent to one of the second surfaces.

2. The method of claim 1 further including measuring the pressure within the mold cavity prior to moving the slide to the engaged position and moving the slide to the engaged position only after the pressure within the mold cavity reaches a pre-determined level.

3. The method of claim 2 further including providing a pressure transducer and mounting the pressure transducer so as to be in communication with the molten plastic.

4. The method of claim 3 further including mounting the pressure transducer in close proximity to a gate introducing the molten plastic into the mold cavity.

5. The method of claim 2 further including heating the slide to a pre-determined temperature prior to moving the slide to the engaged position.

6. The method of claim 5 further including heating the slide to a temperature in the range of 23° Celsius to 240° Celsius.

7. The method of claim 1 wherein each of the second surfaces defines a gradual transition to the thinnest part of the thin walled section and which prevents formation of sinks in the surface of the plastic part.

8. The method of claim 1 wherein moving of the slide is done at a rate that is variable.

9. The method of claim 1 further comprising the step of retracting the slide prior to the step of opening the mold halves.

10. The method of claim 9 wherein the retracting step is performed during the step of allowing the molten plastic to cool.

11. A method of forming a thin walled section in an injection molded plastic part comprising:

providing a mold having a first mold half, a second mold half, and a slide, wherein the first mold half, the second mold half, and the slide define a mold cavity when assembled and the slide includes a double angled step that defines a thin walled section of the plastic part, the slide being movable between a retracted position, wherein the double angled step that defines the thin walled section is partially retracted from the mold cavity and an engaged position wherein the double angled step that defines the thin walled section is in position to define the final shape of the plastic part;

injecting molten plastic into the mold cavity with the slide in the retracted position;

measuring the pressure within the mold cavity with a pressure transducer mounted so as to be in communication with the molten plastic;

heating the slide to a pre-determined temperature in the range of 23° Celsius to 240° Celsius;

moving the slide to the engaged position after the pressure within the mold cavity reaches a pre-determined level such that the double angled step forms a gradual transition to the thin walled section;

allowing the molten plastic to cool;

opening the mold halves and removing the plastic part; and

wherein each half of the double angled step is comprised of a first surface that defines a first angle with respect to the slide movement direction that is less than ninety degrees and a second surface that defines a second angle with respect to the slide movement direction that is greater than the first angle but less than ninety degrees, wherein one end of each of the first surfaces defines a thinnest part of the thin walled section and an opposite end of each of the first surfaces being adjacent to one of the second surfaces.

12. The method of claim 11 further including mounting the pressure transducer in close proximity to a gate introducing the molten plastic into the mold cavity.

13. The method of claim 11 wherein the gradual transition to the thin walled section prevents formation of sinks in the surface of the plastic part.

14. The method of claim 11 wherein moving of the slide is done at a rate that is variable.

15. The method of claim 11 further comprising the step of retracting the slide prior to the step of opening the mold halves.

16. The method of claim 15 wherein the retracting step is performed during the step of allowing the molten plastic to cool.