Overmolding tooling and method for making flexible substrate assemblies

Abstract

This application relates to overmolding specific tooling and methods for making flexible substrate assemblies. A method for overmolding a tubular structure includes inserting a core pin into the tubular structure such that at least a portion of a body of the core pin extends at least partially out of the tubular structure. The method further includes clamping the tubular structure to a mold cavity structure in a Z direction using a holding structure, where the holding structure includes a ramped portion and a flexible portion extends out of the mold cavity structure. The method also includes injecting a thermoplastic material into a mold cavity of the mold cavity structure to overmold at least a portion of the tubular structure, where the injecting of the thermoplastic material includes the thermoplastic material contacting the portion of the core pin extending from the tubular structure.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a method for forming an overmolded flexible substrate assembly over a tubular structure and overmolding the tubular structure. More specifically, the present disclosure relates to a method for injection molding an overmolded assembly using overmolding specific tooling and a tubular structure having an injection molded overmolded assembly. The overmolded assembly can be a sheath of a catheter or stent or connector that is part of a connection assembly for transferring fluids, for example, from chemical and / or biological processes through several different pieces of tubing, couplings, and / or storage vessels. BACKGROUND

[0002] Methods and apparatus for injection molding objects are well known. For example, a mold cavity having the shape of a desired object is created in at least two parts, and a liquidized material is injected into the mold cavity. Then, the liquidized material is allowed to solidify and the final molded object is removed from the mold.

[0003] In some instances, the molded object is a tubular structure that requires, for example, a hollow portion to form a piece of tubing, a tube, a connector of tubing and tubes, or other similar tubular structure, where traditional processing methods use a core pin with support features to hold the core pin in place during the injection molding process. In such cases, the solid core pin typically requires some type of locking mechanism that abuts the back end of the core pin to provide resistance against the high pressure provided during injection of the liquidized material to maintain the positioning of the core pin. The maintenance of the core pin helps to reduce / eliminate flash, for example, to prevent the liquidized material from entering the hollow portion of the molded object at the intersection of the core pin or forming in the hollow portion. By reducing or eliminating flash, interruptions in the flow path in the tubular structure that can lead to failure, such as a leak, break, or rupture, and / or defects in the molded assembly can be avoided. In other prior art injection molding processes, threaded core pins are used, but because the core pin is not held, flash can occur between the tubular structure and the core pin.

[0004] Furthermore, because some prior injection molding methods use core pins that are solid mandrels with a long length, for example, a solid metal portion, such as a mandrel that can be as long as 36", the core pin extends out of the mold, such that injection molding of the tubular structure requires a large press size. Additionally, due to the length of the solid mandrel core pin, the core pin is difficult to manage and results in a complex process for core pin interchange for overmolding different lengths of tubular structures. Moreover, given the long length of the core pin, the core pin is difficult to remove from the tubular structure and can therefore cause damage to the tubular structure when attempting to remove the core pin.

[0005] That is, existing injection molding processes have problems when forming a tubular structure with an overmolded component, where existing molding equipment / molds are insufficient to reduce or prevent overflow of liquefied material, and further require the use of overmold tools that are difficult to manage because of their large footprint size and the use of long core pins that are difficult to manage, remove, and / or extract, solid core material. SUMMARY

[0006] In an embodiment, a method for overmolding a tubular structure is provided. The method includes the steps of overmolding a polymeric connector onto two or more polymeric tubular structures by preloading a force onto the two or more tubular structures each having an internal core pin to cause the internal core pin to not move in a first mold cavity, while combining a second mold cavity and injection molding the connector.

[0007] In another embodiment, a method for overmolding a tubular structure includes inserting a core pin into the tubular structure such that at least a portion of a body of the core pin extends at least partially out of the tubular structure, where the core pin includes the body and a flexible portion connected to the body and the flexible portion extends out of the tubular structure. The method further includes clamping the tubular structure to a mold cavity structure in a Z-direction and / or a containment direction using a holding structure, where the holding structure includes a ramped portion and the flexible portion extends out of the mold cavity structure. The method also includes injecting a thermoplastic material into a mold cavity of the mold cavity structure to overmold at least a portion of the tubular structure, where the injecting of the thermoplastic material includes the thermoplastic material contacting the portion of the core pin extending from the tubular structure.

[0008] The details of one or more embodiments of the disclosure are set forth in the accompanying drawings and the detailed description. BRIEF DESCRIPTION OF DRAWINGS

[0009] Reference is made to the accompanying drawings that form a part of this disclosure, and which illustrate embodiments of the systems and methods described in this specification.

[0010] Figure 1 is a perspective view of a specialized molding tool according to an embodiment.

[0011] Figure 2 is a cross-sectional view of the specialized molding tool in Figure 1 before connecting the upper and lower halves of the molding apparatus.

[0012] Figure 3 is a cross-sectional view of the holding structure of the specialized molding tool in Figure 2 along line 3-3.

[0013] Figure 4is a cross-sectional view of a perspective view of a specialized molding tool in Figure 1

[0014] Figure 5 is Figure 1 is a cross-sectional view of a perspective view of a specialized molding tool in

[0015] Figure 6 is Figure 1 is a cross-sectional view of a perspective view of a specialized molding tool in

[0016] Figure 7 is Figure 1 is a perspective view of an embodiment of a retention structure of a specialized molding tool in

[0017] Figure 8 is Figure 7 is an end view of an embodiment of a retention structure of a specialized molding tool in

[0018] Figure 9 is Figure 1 is a cross-sectional view of another embodiment of a retention structure of a specialized molding tool in

[0019] Figure 10 is Figure 1 is a perspective view of another embodiment of a core pin retention system of a specialized molding tool in

[0020] The same numbers are used to represent the same features. DETAILED DESCRIPTION

[0021] This application is related to U.S. Application No. 62 / 274,357 entitled “Overmolded Tubing Connectors,” which is incorporated by reference herein in its entirety.

[0022] ​The present disclosure relates to a method for forming an overmolded flexible substrate assembly over a tubular structure and overmolding a tubular structure. More specifically, the present disclosure relates to a method for injection molding an overmolded assembly using an overmolding specific tool and a tubular structure having an injection molded overmolded assembly. The overmolded assembly can be a connector, which is part of a connection assembly for transferring fluids, for example, from chemical and / or biological processes, through several different pieces of tubing, couplings, and / or storage vessels. While the specific injection molding method for forming a tubular structure having an overmolded assembly as a connector is discussed below with respect to a fluid connection assembly, it should be understood that this discussion is not intended to limit the scope of the present disclosure, but is provided as an embodiment thereof. For example, in embodiments, the injection molding method can also be used to form a catheter, stent, other piece of tubing connection of a fluid assembly, or other tubular structure having a hollow core and overmolded assembly for transferring fluids.

[0023] Figure 1 and 2 An example embodiment is described for providing an overmolding specific processing equipment for providing a tubular structure having an overmolded assembly with a hollow portion to form, for example, a piece of tubing, a tube, a connector of a piece of tubing and a tube, a catheter, a stent, or other similar tubular structure that can be used to transfer fluids. In embodiments, the injection molding process includes injecting a liquefied polymeric material for overmolding at least one tubular structure, but preferably for forming an overmolded connector of two or more tubular structures. The injection molding process includes using a specific processing molding equipment 10 that includes a lower half 20 and an upper half 30, where the lower half 20 and the upper half 30 have complementary structures for injection molding. It should be understood that when the lower half 20 and the upper half 30 are connected or joined, a sealed mold cavity is formed for receiving the injected liquefied polymeric material to form an overmolded assembly or portion over the tubular structure.

[0024] The lower half 20 of the molding equipment 10 includes a lower half mold cavity 22 for receiving at least one tubular structure 40 and a core pin 50. The lower half mold cavity 22 includes a predetermined shape half for forming an overmolded assembly or portion over the tubular structure 40 and the core pin 50. The lower half 20 further includes at least one retention structure 24 for clamping and / or holding the position of the tubular structure 40 to prevent the tubular structure 40 from moving during the injection molding process. It should be understood that while two retention structures 24 are described, the number of retention structures 24 can vary depending on the number of tubular structures and / or whether preloading forces are needed for overmolding of the tubular structures, as discussed further below. The lower half 20 of the molding equipment 10 can also include additional structures, such as guide bushings, cooling systems, guide pins / guides, or the like, the disclosure of which is not necessary to understand the overmolding method of the present disclosure. Figure 1 and 2 While two retention structures 24 are described, the number of retention structures 24 can vary depending on the number of tubular structures and / or whether preloading forces are needed for overmolding of the tubular structures, as discussed further below. The lower half 20 of the molding equipment 10 can also include additional structures, such as guide bushings, cooling systems, guide pins / guides, or the like, the disclosure of which is not necessary to understand the overmolding method of the present disclosure.

[0025] The upper half 30 of the molding apparatus 10 includes an upper mold cavity 32 having a predetermined shape of a complementary half for forming an overmolded assembly or portion over the tubular structure 40 and the core pin 50, an abutment structure 34 having a complementary geometry for engagement with the retaining structure 24 (e.g., opposing angled surfaces), and a clamping portion 36 for clamping or holding the tubular structure, e.g., configured to hold or retain the tubular structure 40 in at least the Z-direction and / or the containment direction during the injection molding process. The upper half 30 of the molding apparatus 10 can also include additional structures, e.g., mold springs, cooling systems, guide pins or posts, ejector pins / plates, positioning rings, thermoplastic inlets, or the like.

[0026] The predetermined shape of the mold cavity can be any shape for forming an overmolded assembly or portion over the tubular structure and the core pin preformed in the mold or provided as an insert inserted into the molding apparatus 10. For example, the shape can be for creating an overmolded assembly of a catheter, a dilator, a fastener, a needle, a connector, a luer, a hub, a cannula, or the like. In embodiments, the overmolded portion can have a shape for forming a sheath or balloon over a tube to form a catheter or for forming a sheath over a cannula of a stent.

[0027] In embodiments, the predetermined shape is for a connector of a fluid connection system, where the connector has at least two connector portions. The at least two connector portions extend from a center of the connector and have a first end connected to the center of the connector and a second open end connected to a second end of one of the plurality of tubes, and where each of the at least two connector portions is formed tapered, where the outer diameter of the first end at the center of the connector is greater than the outer diameter of the second end of the connector portion in a manner such that the connector portion has flexibility. The connector portions are continuously formed from the tubular structure such that an internal flow path is continuously formed between the connector portions and the tubular structure. Because the overmolded assembly is overmolded over the tubular structure, the internal flow path of the connector portions and the outer surface configuration of the tubular structure are complementary such that the tubular structure is capable of being at least partially disposed within the connector portions. Thus, the connector portions of the connector are fluidly connected to each other and the plurality of tubular structures through the center of the connector. It should be appreciated that while in this embodiment the connector has an internal flow path having an inner diameter equal to or similar to the inner diameter of the tubular structure, the connector can also have an internal flow path having an inner diameter greater than or less than the inner diameter of the tube, depending on the requirements for transferring the drug or biological fluid. That is, the size of at least the inner diameter of the connector and / or the tubular structure is volume dependent, e.g., the connector can be sized to function as a pressure reducer, a dilator, or a combination thereof.

[0028] The connectors can have strain relief portions to further increase the flexibility of the connectors. For example, each connector portion can include a plurality of rib segments provided along an outer surface of the tapered connector portion. The plurality of rib segments are provided in a parallel arrangement along a length direction of the connector portion, with the rib segments provided closest or nearest to a center of the connector having an outer diameter that is greater than the rib segments provided at a second end of the connector portion. With this structure, the connector portions of the connector are able to be further articulated (e.g., moved) such that as the tubular structure is moved or adjusted, the connector portions are articulated and / or bent such that the tubular structure does not experience stress, which prevents restrictions from being formed in the flow path. That is, because kinks in the tubular structure and / or crushing or buckling of the tubular structure are not created, the flow transition between the connector and the tubular structure is maintained, such as maintaining a smooth flow curvature along the flow path.

[0029] It should be appreciated that the connectors can have different configurations, for example, the connectors can have four connector portions provided as a four-arm cross design, or the connectors can include a plurality of connector portions arranged in any combination of a four-arm cross mold design, a six-arm cross mold design (or star mold design), a T-mold design, a y-mold design, an elbow mold design, or combinations thereof. The connector design configuration can be selected based on the number of bag assemblies that need to be filled, the layout of the bag assembly or processing equipment, or other design considerations. For example, the connectors can be configured as a reducer, an expander, or combinations thereof as needed to connect different sized tubing or components.

[0030] The retaining structure 24 can be any device that provides a clamping or retaining force in at least the Z-direction and / or the containment direction (e.g., perpendicular and / or horizontal to the molding apparatus 10) for clamping and / or retaining the positioning of the tubular structure 40 during the injection molding process. The retaining structure 24 can also be configured to retain the positioning of the core pin 50 or provide a preloading force on the core pin 50 during the injection molding process. For example, in an embodiment, the retaining structure 24 can include an upper half and a lower half, where at least the lower half is connected to or otherwise positioned in the lower half 20 of the molding apparatus 10, e.g., in a cavity or opening that can be secured to the lower half 20 using a insert, screw, pin, or the like. The upper half and lower half of the retaining structure 24 can be brought together using screws, bolts, latches, or other fastening devices to engage them. Thus, when the upper half and lower half of the retaining structure 24 are fastened or attached together, the inner surface of the retaining structure 24 clamps and / or retains the tubular structure 40 to provide a force in the Z-direction and / or the containment direction for maintaining the positioning of the tubular structure 40. The retaining structure 24 can also include a sloped portion 25 on the upper half for engaging the abutment structure 34 of the upper half 30 of the molding apparatus 10 and a spring 220 provided in the lower half of the retaining structure 24 that abuts the lower half 20 of the molding structure 10. It should be appreciated that the sloped portion 25 of the retaining structure has a surface that is inclined between 5 to 80 degrees and preferably between 10 to 40 degrees with respect to a plane perpendicular to the retaining structure. The angle of inclination of the sloped portion 25 of the retaining structure 24 can depend on the predetermined amount of force required to balance the molding pressure exerted by the pressurized liquefied polymeric material applied to the core pin to maintain the positioning of the core pin during the injection molding process.

[0031] In an embodiment, the core pin 50 having a body or mandrel 211 and a flexible portion 212 connected to the body 211 can be used with the molding apparatus 10. The body 211 of the core pin 50 can have a tapered structure, e.g., one end of the body 211 has a diameter that is greater than the diameter of the remaining portion of the body 211. The body 211 having a tapered structure can include an indication or demarcation to facilitate positioning the body 211 in the tubular structure 40 such that a majority of the body 211 is inserted into the tubular structure 40 and a portion of the body 211 extends at least partially out of the tubular structure 40. The indication or demarcation can correspond to a portion of the body 211 that has a diameter that is greater than the remaining portion of the body to create a fluid-tight seal between the body 211 of the core pin 50 and the hollow portion of the tubular structure 40. In an embodiment, the flexible portion 212 also extends out of the tubular structure 40 with a majority of the body 211 positioned or oriented within the tubular structure 40.

[0032] It should be understood that, in the embodiments, the taper of the body 211 is provided such that a portion of the body 211 having a smaller diameter is at least partially positioned within the undercut region of the retaining structure 24, wherein the undercut region has an inner surface having a geometry different from that of the remainder of the retaining structure 24, such that the tubular structure 40 is at least partially deformed in the undercut region. For example, as Figure 3 As seen, the tubular structure 40 has an outer surface with an initial geometry A that is substantially circular. However, as the undercut region of the retaining structure 24 closes, the tubular structure 40 is at least partially deformed to have a different outer surface geometry B (e.g., flattened), which differs from the geometry of the outer surface of the tubular structure not positioned in the retaining structure 24. This increases the frictional engagement between the retaining structure 24, the tubular structure 40, and the body 211 of the mandrel 50. Thus, not only does the undercut region of the retaining structure 24 provide an interference fit to hold the tubular structure in place to prevent it from recoiling due to mold pressure during the injection molding process, but the holding and deformation of the tubular structure 40 also provides a sealing effect to prevent liquefied material from the injected thermoplastic material from entering the retaining structure 24. In an embodiment, the taper of the body 211 of the mandrel 50 can also be provided such that a portion of the body 211 with a larger diameter is positioned in the area between the retaining structure 24 and the mold cavity to further provide a sealing effect to prevent liquefied material from entering the retaining structure 24.

[0033] To further facilitate the isolation of the retaining structure 24 from the liquefied material, the geometry of the inner surface of the retaining structure 24 at one end of the tubular structure 40 may differ from the geometry of the molding surface of the cavity 22 adjacent to the retaining structure 24, for example, in the transition portion between the retaining structure 24 and the cavity 22 / 32 used to form the covering molding assembly. For instance, the inner surface of the retaining structure 24 may be oval, while the molding surface may be circular. Therefore, when the upper half 30 is combined with the lower half 20 of the molding apparatus, the tubular structure 40 has a different outer surface geometry between the cavity 22 and the retaining structure 24, further sealing the liquefied material within the cavity of the molding apparatus 10.

[0034] The body 211 may be made of stainless steel, copper, titanium, nickel, aluminum, tungsten carbide, steel nitride, flexible nickel-titanium, their alloys, and combinations thereof. It should be understood that the body 211 may include coatings, surface texturing, or the like to facilitate positioning and guiding the body 211 within the tubular structure 40.

[0035] The flexible portion 212 can be a wire, flexible tubing, or cable made of hard plastic, steel, stainless steel, aluminum, alloys thereof, multiple steel wire ropes or lines, or the like. The flexible portion 212 can include a bullet-shaped end for insertion into the tubular structure and / or to facilitate removal or extraction of the core pin 50 from the tubular structure 40. It should be appreciated that because the core pin 50 includes at least the flexible portion 212, an improvement over existing designs of injection molding machines / devices is provided because the length of the core pin can be managed such that the size and / or footprint occupied by the injection molding machine / device can be reduced and the length of the core pin can be adjusted to allow overmolding of tubular structures of various lengths. That is, in existing designs of injection molding machines / devices, various steel core pins or mandrels having different lengths (e.g., 6 inches, 1 foot, and up to 3 feet) are provided for overmolding tubular structures of various lengths. Because the core pin or mandrel made of a solid metal portion is inserted into the tubular structure and braced such that the core pin or mandrel does not displace from the tubular structure during the injection molding process, one end of the core pin or mandrel extends out of the tubular structure and the injection molding equipment. The length of the solid metal core pin or mandrel not only creates an increased footprint size for the molding equipment, but also results in a complex process to manage the use of the core pin or mandrel with the tubular structure.

[0036] On the other hand, in embodiments, because the core pin 50 of the present disclosure includes the flexible portion 212, the core pin can be used with potentially unlimited lengths of tubular structures, for example, depending on the length of the flexible portion, because only the body of the core pin 50 is clamped and positioned in or near the mold cavity and subjected to the molding pressure during the injection molding process. Additionally, because the flexible portion 212 is used to insert into the tubular structure and position the body 211 of the core pin 50, the core pin 50 is easier to install and manage than existing solid steel mandrels. Moreover, the flexible portion 212 is capable of being wound or otherwise positioned using a holding system such that the flexible portion 212 does not interfere with the molding machine / device during the injection molding process (e.g., wound on a spool or clamped or clipped at the sides of the molding equipment) to provide a more compact molding equipment where the press size footprint can be minimized, for example, a smaller molding equipment.

[0037] Reference Figures 1 to 4 Embodiments of a method of overmolding a tubular structure using the specialized machining molding equipment 10 are discussed below. While the figures illustrate a complete tubular structure and overmolding assembly forming a fluid connector to more easily understand the present disclosure, the description below generally relates to a method for forming an overmolding assembly. Additionally, because the structure and function of the left and right sides of the molding equipment 10 are similar, the description provided herein is with respect to one side. The injection molding process can also be used to overmold tubular structures of various products without departing from the scope of the present disclosure.

[0038] First, the tubular structure 40 is prepared by inserting the core pin 50 into the tubular structure 40. For example, the flexible portion 212 can be inserted into the tubular structure 40 and pulled through the tubular structure 40 such that the body 211 of the core pin 50 is engaged within the hollow portion of the tubular structure 40. Thus, as the flexible portion 212 of the core pin 50 is pulled through the tubular structure 40, the tubular structure 40 engages the body 211 until one end of the tubular structure 40 is positioned, for example, at or near an indication or demarcation of the body 211.

[0039] After the core pin 50 is inserted into the tubular structure 40, the combined tubular structure 40 and core pin 50 are positioned in the lower mold cavity 22. Then, the retaining structure 24 is closed to clamp at least a portion of the body 211 of the core pin 50 and the tubular structure 40 by providing a force in at least the Z-direction and / or the containment direction to clamp and / or retain the tubular structure 40 within the lower half 20 of the molding apparatus 10. For example, the retaining structure 24 closure provides an interference fit to maintain the positioning of the tubular structure, as discussed above, for example, the tubular structure is deformed to increase the frictional engagement between the retaining structure 24 and the tubular structure 40 and the core pin 50.

[0040] In another step, as Figure 4As explained above, the upper half 30 combines with the lower half 20 of the molding apparatus 10 to create a sealed mold cavity for overmolding a tubular structure 40 and a core pin 50 having a predetermined shape. For example, in embodiments, a thermoplastic material is fed and injected into the sealed mold cavity such that the thermoplastic material contacts at least a portion of the core pin extending from the outer surface of the tubular structure and the tubular structure in the sealed mold cavity such that the overmolded assembly includes a hollow portion in fluid connection with the tubular structure. The thermoplastic material can be fed from a hopper and melted and supplied at a molding pressure of between 5,000 to 50,000 PSIG and preferably about 10,000 PSIG. The thermoplastic material can be selected from a variety of thermoplastic polymers and / or thermoset elastomers such that the tubular structure and overmolded portion are flexible. For example, the tubular structure and overmolded portion can be formed from a thermoplastic polymer selected from the group consisting of: a fluoropolymer, a polyurethane, a vulcanized rubber, a flexible polyvinyl chloride (PVC), a thermoplastic elastomer (TPE), a high-density polyethylene (HDPE), an ethylene vinyl acetate (EVA), a copolymer / polyolefin, a high-impact polystyrene (HIPS), a polypropylene (PP), an acrylonitrile butadiene styrene (ABS), a polytetrafluoroethylene (PTFE or ETFE), or mixtures thereof, or a thermoset elastomer (e.g., liquid silicone rubber (LSR)) or mixtures thereof. Thus, the tubular structure and overmolded assembly can be made from a material that remains flexible even at low temperatures (e.g., -196°C). The tubular structure and connector can be made from the same material or different materials, but generally are made from materials that are compatible, e.g., the tubular structure and overmolded assembly have similar or the same coefficients of thermal expansion / contraction, similar melting temperatures and flow characteristics, the same chemical resistance or compatibility, and / or other properties required for the application of the fluid connection assembly, e.g., UV blocking and the like. The tubular structure and overmolded assembly can also be made from a material that is relatively inert (e.g., does not filter or significantly absorb a drug or biological fluid) and / or non-reactive.

[0041] After the overmolded assembly or portion 430 is continuously formed and solidified from the tubular structure 40, the upper half 30 of the molding apparatus 10 can be separated from the lower half 20 and the tubular structure 40 and overmolded portion 430 can be removed from the holding structure 24 and mold cavity. The core pin 50 can then be removed and / or extracted from the tubular structure 40 by engaging the flexible portion 212 of the core pin 50 and providing a force in the X-direction away from the overmolded portion 430. The tubular structure 40 with the overmolded portion can be engaged, e.g., using a holding device that clamps around the overmolded portion 430 to provide a force in the opposite direction of the force provided to the flexible portion 212. In embodiments, a device or tool having a slit and / or opening can be used to engage the bullet-shaped end of the flexible portion 212 to engage it to facilitate removal of the core pin 50 from the tubular structure 40.

[0042] In another embodiment, additional steps are provided to create a preload force on the tubular structures and the core pin. For example, Figures 1 to 4 The molding apparatus of FIG. 1 can be used to manufacture a fluid connection assembly having a plurality of tubes or tubular structures and an overmolded connector connecting the plurality of tubes or tubular structures. For example, a method includes overmolding a polymeric connector onto two or more polymeric tubular structures by preloading a force onto the two or more tubular structures each having an internal core pin to cause the internal core pin to not move in a first mold cavity while incorporating a second mold cavity and injection molding to form the overmolded connector.

[0043] For example, similar to the method described above, a first tubular structure 40 is first prepared by inserting a first core pin 50 having a first body or mandrel 211 and a first flexible portion 212 into the first tubular structure 40. The first flexible portion 212 is inserted into and pulled through the first tubular structure 40 such that the first body 211 of the first core pin 50 is engaged within the hollow portion of the first tubular structure 40. As the first flexible portion 212 of the first core pin 50 is pulled through the first tubular structure 40, the first tubular structure 40 engages the first body 211 until an end of the first tubular structure 40 is positioned or aligned near an indication or demarcation on the first body 211. The first flexible portion 212 also extends out of the first tubular structure 40 with a majority of the first body 211 positioned or oriented within the first tubular structure 40.

[0044] Similarly, a second tubular structure 40 is prepared by inserting a second core pin 60 having a second body and a second flexible portion into the second tubular structure 40 such that at least a portion of the second body of the second core pin 60 extends at least partially out of the second tubular structure 40. The second body having a tapered structure can also include an indication or demarcation to facilitate positioning of the second body in the second tubular structure 40 such that a majority of the second body is inserted into the second tubular structure 40 and a portion of the second body extends at least partially out of the second tubular structure 40. In embodiments, the second flexible portion also extends out of the second tubular structure 40 with a majority of the second body positioned or oriented within the second tubular structure 40. It should also be appreciated that in embodiments, the second core pin can connect two tubular structures 40 by extending the second body to connect the two tubular structures 40.

[0045] Next, the first core pin 50 and the first tubular structure 40 are combined, and the second core pin 60 and the second tubular structure 40 are combined and positioned in the lower mold cavity 22, such that one end of the first core pin 50 in the first tubular structure 40 abuts against the second core pin 60 in the second tubular structure 40 to form an intersection or abutment between the core pins at the central portion of the mold cavity. For example, in an embodiment, one end of the first core pin 50 has a geometry corresponding to the outer surface geometry of the second core pin 60, for example, having a crescent-shaped end capable of engaging and aligning the cylindrical outer surfaces of the first core pin 50 and the second core pin 60 in position. That is, the second core pin 60 may include a body that traverses the entire mold cavity and connects the two tubular structures 40 to provide a contact point (e.g., the outer surface of the core pin body) to create a knot or intersection where one end of the first core pin 50 engages with the second core pin 60. It should be understood that the end of the first pin may have a corresponding geometry or shape that engages with the second pin 60 to align the first pin 50 and the second pin 60 in position, such as a mating or blocking end, a C-shape, a pin, a star, or the like.

[0046] like Figure 2 As seen, the first tubular structure 40 and the first mandrel 50 can then be clamped to the lower half 20 of the molding apparatus 10 by means of the closed retaining structure 24. It should be understood that clamping the first tubular structure and the first mandrel also creates an increased engagement between the first mandrel and the first tubular structure by providing force in at least the Z direction and / or the receiving direction to clamp and / or retain the first tubular structure 40 within the lower half 20 of the molding apparatus 10, for example by providing an interference fit to at least maintain the positioning of the first tubular structure and the first mandrel.

[0047] In one embodiment, the first body 211 may be tapered such that a portion of the first body 211 with a smaller diameter is at least partially positioned within the undercut region of the retaining structure 24, wherein the undercut region may have an inner surface with a geometry different from the remainder of the retaining structure, such that the first tubular structure 40 is at least partially deformed within the undercut region. Thus, not only does the undercut region of the retaining structure 24 provide an interference fit to hold the first tubular structure 40 in place to prevent it from recoiling due to molding pressure during the injection molding process, but the holding and deformation of the first tubular structure 40 also provides a sealing effect to prevent liquefied material from entering the retaining structure 24 during the injection molding process. In another embodiment, the taper of the first body 211 of the first core pin 50 may be further provided such that the first body 211 with a larger diameter is positioned in the area between the retaining structure 24 and the mold cavity to further provide a sealing effect to prevent liquefied material from entering the retaining structure 24.

[0048] To further promote the isolation of the retention structure 24 from the liquefied material, the geometry of the inner surface of the retention structure 24 at one end of the first tubular structure 40 can be different from the geometry of the molding surface of the mold cavity 22 adjacent to the retention structure 24, e.g., the transition between the retention structure 24 and the mold cavity 22 / 32 for forming the overmolded assembly. Thus, when the upper half 30 is combined with the lower half 20 of the molding apparatus, the first tubular structure 40 has a different outer surface geometry between the mold cavity 22 and the retention structure 24, such that the liquefied material is further sealed within the mold cavity of the molding apparatus 10.

[0049] In another step, as explained in Figure 4 , the upper half 30 is combined with the lower half 20 of the molding apparatus 10 to create a sealed mold cavity for overmolding the first tubular structure and the second tubular structure, e.g., a connector, having a predetermined shape. In embodiments, the upper half 30 includes a clamping portion 36 for clamping and retaining the second tubular structure 40 in the molding apparatus at least in the Z-direction and / or the accommodation direction. The clamping portion 36 can have the same or similar features as the retention structure 24 for clamping and / or retaining the second tubular structure, e.g., an undercut region or a deformed portion, and preventing the liquefied material from the injection of the thermoplastic material from entering the clamping portion 36, e.g., having a different inner surface geometry than the mold cavity and / or another portion of the clamping portion 36.

[0050] As the upper half 30 is combined with the lower half 20 of the molding apparatus 10, the abutment structure 34 of the upper half 30 engages the inclined surface 25 of the retention structure 24 in the lower half 20, such that a preloading force in the X-direction is generated on the first core pin 50 towards the second core pin 60. For example, as seen in Figure 2 , a gap "g" is provided between the retention structure 24 and the mold cavity 22 of the molding apparatus 10, and as seen in Figure 5 and 6 , the retention structure includes a bolt 220 provided in a cavity of the lower half of the retention structure adjacent to the lower half 20 of the mold cavity 22. When the spring 220 is in a relaxed state, the spring 220 maintains a play or distance of the gap "g". As the upper half 30 is combined with the lower half 20 of the molding apparatus 10, as seen in Figure 4 , 5As seen in Figs. 6, the abutment structure 34 engages the angled portion 25 of the retention structure 24 such that the retention structure 24 moves or slides in the X-direction and the spring 240 is compressed. When the spring is fully compressed, for example, when the gap "g" is reduced to near zero or to zero (e.g., the spacing between the molding apparatus and the retention structure is tight or small), the total predetermined preload force is provided. The initial gap distance "g" is provided at a distance between 0.001 inch to 0.10 inch and preferably about 0.03 inch such that the retention structure 24 can move or slide toward the mold cavity to create the desired amount of preload force. As such, because the retention structure 24 clamps or holds the first tubular structure 40 and the first core pin 50, the first core pin 50 in the first tubular structure is subjected to the preload force. Thus, the first core pin 50 is maintained against and / or against the second core pin 60 at the intersection between the first core pin 50 and the second core pin 60 in the mold cavity even when subjected to the molding pressure during the injection molding process. The gap "g" can also be provided such that the positive timing of the retention structure 24 creates an incremental preload force between the first core pin 50 and the second core pin 60 until the total preload force is provided during the joining of the upper half 30 and the lower half 20 of the molding apparatus 10, for example, as the upper half 30 is joined with the lower half 20. It should be appreciated that in embodiments, the upper half 30 of the molding apparatus 10 can include a spring and compression device to prevent the retention structure 24 from moving vertically during the joining of the upper half 30 and the lower half 20 of the molding apparatus 10. It should also be appreciated that the gap "g" and the angle of the angled portion 25 of the retention structure 24 can be adjusted together to provide the desired predetermined amount of force (or incremental amount of force) to be applied to the core pin to maintain the positioning of the core pin to balance the molding pressure applied by the pressurized liquefied polymeric material during the injection molding. That is, the retention structure 24 can be designed with or replaced with the appropriate angle of the angled portion and the gap "g" depending on the predetermined amount of force needed to balance the molding pressure, the material of the tubular structure, the material of the injected polymeric material, or the like.

[0051] Next, a thermoplastic material is fed and injected into the mold cavity formed by the lower mold cavity 22 and the upper mold cavity 32 such that the thermoplastic material contacts at least a portion of the first core pin extending from the first tubular structure and the second core pin extending from the second tubular structure to overmold the core pins and the tubular structures to form a connector fluidly connecting the first tubular structure and the second tubular structure. The thermoplastic material can be fed from a hopper and melted and supplied at a pressure between 5,000 to 50,000 PSI and preferably about 10,000 PSIG. The thermoplastic material can be selected from various thermoplastic polymers and / or thermoset elastomers such that the tubular structures and overmolded portions are flexible. For example, the tubular structures and overmolded portions can be formed from a thermoplastic polymer selected from the group consisting of: a fluoropolymer, a polyurethane, a vulcanized rubber, a flexible polyvinyl chloride (PVC), a thermoplastic elastomer (TPE), a high-density polyethylene (HDPE), an ethylene vinyl acetate (EVA), a copolymer / polyolefin, a high-impact polystyrene (HIPS), a polypropylene (PP), an acrylonitrile butadiene styrene (ABS), a polytetrafluoroethylene (PTFE or ETFE), or mixtures thereof, or a thermoset elastomer (e.g., liquid silicone rubber (LSR)) or mixtures thereof. Thus, the tubular structures and overmolded portions are made from materials that remain flexible even at low temperatures (e.g., -196°C). The tubing and connectors can be made from the same material or different materials, but generally are made from materials that are compatible, e.g., the tubular structures and overmolded portions have similar or the same coefficients of thermal expansion / contraction, similar melting temperatures and flow characteristics, the same chemical resistance or compatibility, and / or other properties required for the application of the fluid connection assembly, e.g., UV blocking and the like. The tubular structures and overmolded portions can also be made from materials that are relatively inert (e.g., do not filter or significantly absorb drugs or biological fluids) and non-reactive.

[0052] After the overmolded portion 430 is continuously formed and solidified from the tubular structure 40, the upper half 30 of the molding apparatus 10 can be separated from the lower half 20 and the tubular structure 40 and overmolded portion 430 can be removed from the holding structure 24 and the molding apparatus 10. As the upper half 30 is separated from the lower half, the spring 220 returns the holding structure 24 to a neutral or initial position to allow a subsequent pre-load force to be provided on the subsequent core pin for a subsequent overmolding operation. Next, the first core pin 50 can be removed and / or extracted from the first tubular structure 40 by engaging the flexible portion 212 of the first core pin 50 and providing a force in the X-direction away from the overmolded portion 430. Next, the second core pin 60 can be removed and / or extracted from the second tubular structure by engaging the flexible portion 212 of the second core pin 60 as discussed in the above embodiments.

[0053] Next, a dedicated overmolding tool can be used for a subsequent overmolding operation, such as forming a spine assembly of a fluid connection assembly. Specifically, the dedicated machining and overmolding method allows for forming a connector on a tubular structure in a one-step molding operation, such that after at least one tubular structure is overmolded with a connector, additional tubular structures can be positioned and subsequently overmolded via the steps described above. By having such features, a repeating structure without inclusions, obstructions, or interruptions can be formed, such that a continuous flow path is provided inside the tubular structure and overmolded connector without the drawbacks of prior art injection molding processes.

[0054] Thus, a dedicated machining apparatus and method for overmolding a tubular structure is provided, which has numerous benefits over prior injection molding processes. For example, in embodiments, a particular slide carrier method is provided that creates a preloading force against the core pins and / or is able to maintain the positioning of the tubular structure to avoid substantial deformation of the tubular structure. That is, the core pins at the intersection / junction between the core pins are preloaded with a force in the X-direction such that the core pins are held and positioned such that during the injection molding process, spillage, such as thermoplastic material intrusion into the tubular structure, is reduced and / or prevented by preventing the core pins from separating. As a result, inclusions, obstructions, or interruptions in the flow path of the connector and tubular structure are mitigated or eliminated, such that a continuous flow path is provided inside the tubular structure and overmolded connector.

[0055] In other words, the methods described herein of forming an overmolded assembly over a tubular structure using the methods and / or molding apparatus described herein have at least the benefit of forming an overmolded assembly with a flow path between the overmolded assembly and the tubular structure that is free of inclusions, obstructions, and / or interruptions, such as having few defects in the overmolded assembly that can lead to failure, such as a leak, break, or rupture. As a result, the methods of forming an overmolded assembly over a tubular structure avoid creating pockets that can accumulate fluid and lead to contamination and cell rupture (e.g., the internal flow path is smooth) or failure while maintaining sufficient pull-out force. Moreover, surprisingly, in some embodiments, because the connector and tubular structure are continuously formed, if the connector and tubular structure are made of the same or similar materials (e.g., have the same or similar thermal properties), then the fluid connection assembly formed therefrom can be used in cryogenic processes while maintaining the structural integrity of the system, such as preventing leaks and / or contamination. For example, the connector is able to withstand impact testing at -196°C, freeze drop testing at -195°C, and is used in freeze-thaw applications.

[0056] It should be understood that although the above description has discussed the retaining structure 24 for clamping the first tubular structure, it should be understood that various modifications of the retaining structure may be used, wherein the retaining structure 24 may be provided with a portion that requires movement of the retaining structure 24 to provide a preload force, such as engaging the outer surface or end of another core pin.

[0057] like Figure 7 As seen in the embodiments, the retaining structure 24 may include a clamshell or hinge design. The retaining structure 24 includes a hinge 710 and a pivot recess 715 connected to the hinge 710, which allows the upper half 740A of the retaining structure 24 to open to allow insertion of the tubular structure 40 and to close with the lower half 740B to clamp or retain the tubular structure 40. The upper half 740A may be coupled to the lower half 740B using a mechanical locking system (e.g., a lever latch, pin, screw, or similar mechanical latching device that allows latching and release of the upper half 740A from the lower half 740B).

[0058] In an embodiment, such as Figure 8 The description indicates that hinge 810 includes a slot 820 that allows the upper half 840A to be raised and lowered relative to the lower half 840B. For example, pivot pin 815 can be raised and lowered in slot 820 to allow the upper half 840A to be raised to accommodate the tubular structure 40 between the upper half 840A and the lower half 840B. Then, the upper half 840A and pivot pin 815 can be lowered to clamp and / or retain the tubular structure 40 in retaining structure 24. It should be understood that the receiving space between the upper half 840A and the lower half 840B may have an inner surface with different shapes for clamping and / or retaining the tubular structure 40. For example, in an embodiment, the receiving space has a non-circular profile (e.g., a roundness between 0.9 and 0.99 and / or a roundness between 0.95 and 1.1), such that when the upper half 840A and the lower half 840B are in the clamped position, the tubular structure is at least partially deformed, giving the tubular structure an outer surface geometry different from its initial outer surface geometry (e.g., flattened) to insulate the clamped portion of the tubular structure from the injection thermoplastic material. In a preferred embodiment, the receiving space has a rounded geometry at the upper half 840A and the lower half 840B of the retaining structure 24. However, the receiving space may have other surface geometries that allow the tubular structure 40 to deform to clamp the tubular structure 40 to the molding apparatus 10 without damaging the outer surface of the tubular structure 40. It should be understood that in any of the embodiments, the geometry of the inner surface of the retaining structure 24 may depend on several factors, such as the malleability of the tubular structure, the pressure of the injection molding apparatus, the predetermined force required for the mandrel, or the like.

[0059] In another embodiment, such as Figure 9As seen in FIG. 24, the retention structure 24 includes a collet 924 provided about the tubular structure 40 after the installation of the core pin 50. The collet 924 is a compressible collar made of hard plastic or steel. The collet 924 can be provided against the outer end of the retention structure 24 or within the inner cavity of the retention structure 24. Thus, as the retention structure 24 is moved or slid in the X direction, the collet 924 is compressed to engage the tubular structure 40 and the core pin 50. Therefore, when the retention structure 24 is engaged by the abutment structure of the upper half of the molding apparatus 10, the retention structure 24 is slid or moved toward the molding apparatus to compress the spring 240 and the collet 924 is compressed and slid to provide a pre-load force on the core pin 50 such that one end of the core pin 50 maintains its engagement with the second core pin at the intersection point in the mold cavity during the injection molding process.

[0060] In embodiments, the retention structure 24 can include additional structures or components to increase the frictional contact between the retention structure and the tubular structure. For example, a thin film can be applied to the clamping portion of the retention structure 24 (e.g., silicone or rubber), or a rigid plastic material can be provided between the clamping portion and the tubular structure.

[0061] Further, as discussed above, it should be appreciated that because the core pin includes a flexible portion, the core pin can be used to adapt various lengths for overmolding the tubular structure because the body is the only portion of the core pin that is subject to the molding apparatus clamping and retention during the injection molding. Because the flexible portion is flexible (e.g., is a wire, flexible tubing, cable, or the like), the flexible portion can be moved or wrapped using the retention system to reduce the footprint size of the molding apparatus. Thus, the flexible portion does not interfere with the molding mold / device during the injection molding process, e.g., the flexible portion can be wrapped on a spool or clamped or clipped at the side of the molding apparatus to provide a more compact molding apparatus where the press size footprint can be minimized, e.g., a smaller molding apparatus.

[0062] For example, in one embodiment, as Figure 10 As seen in FIG. 26, the tubular structure 40 with the core pin 50 is placed in the retention structure 24 and the lower mold cavity 22 such that the flexible portion 212 of the core pin 50 extends from the molding apparatus 10. The flexible portion 212 can then be guided or otherwise retained in a spool 1060 provided on the exterior of the clamping apparatus 10. Thus, the flexible portion 212 of the core pin 50 can be positioned or moved to be stored out of the way to provide a more compact molding apparatus. It should be appreciated that in other embodiments of the present application, the flexible portion 212 can also be guided or otherwise retained by a clamp or retaining ring or the like provided on the exterior of the clamping apparatus 10.

[0063] Aspects:

[0064] Any of aspects 1-12 can be combined with any of aspects 13-17, or vice versa.

[0065] Aspect 1. A method for overmolding a tubular structure, comprising: inserting a core pin into the tubular structure such that at least a portion of a body of the core pin extends at least partially out of the tubular structure, wherein the core pin comprises the body and a flexible portion connected to the body and the flexible portion extends out of the tubular structure; clamping the tubular structure to a mold cavity structure in a Z-direction and / or a containment direction using a holding structure, wherein the holding structure comprises a ramped portion and the flexible portion extends out of the mold cavity structure; and injecting a thermoplastic material into a mold cavity of the mold cavity structure to overmold at least a portion of the tubular structure, wherein the injecting of the thermoplastic material includes the thermoplastic material contacting the portion of the core pin extending from the tubular structure.

[0066] Aspect 2. The method of aspect 1, wherein the flexible portion of the core pin is a wire, a flexible tube, or a cable.

[0067] Aspect 3. The method of any of aspects 1-2, wherein the body of the core pin has a tapered structure and an indication on the body of the core pin, wherein the inserting of the core pin includes inserting the flexible portion of the core pin into the tubular structure and aligning an end of the tubular structure with the indication on the body of the core pin, and / or wherein the body includes a portion having a diameter that is less than a diameter of the body of the core pin, wherein the portion having the smaller diameter corresponds to a portion of the tubular structure in the holding structure.

[0068] Aspect 4. The method of any of aspects 1-3, further comprising removing the core pin from the tubular structure by engaging the flexible end of the core pin.

[0069] Aspect 5. The method of any of aspects 1-4, wherein the clamping of the tubular structure to the mold cavity structure includes deforming the tubular structure at least partially such that the tubular structure has an outer surface geometry that is different from an initial outer surface geometry of the tubular structure to insulate the clamped portion of the tubular structure from the injected thermoplastic material.

[0070] Aspect 6. The method of any of aspects 1-5, wherein an inner surface geometry of the portion of the holding structure that contacts an outer surface of the tubular structure is different from a mold surface geometry of the mold cavity adjacent to the holding structure.

[0071] Aspect 7. The method of any one of aspects 1-6, further comprising: inserting a second core pin into a second tubular structure such that the core pin in the tubular structure abuts the second core pin in the second tubular structure to form an intersection; preloading the clamping tubular structure to provide a preloading force on the clamping tubular structure in an X-direction toward the mold cavity structure by engaging the retention structure during a joining of halves of the mold cavity structure such that the core pin in the tubular structure is preloaded against the second core pin and maintains the core pin abutting to the second core pin during the injection of the thermoplastic material, wherein the engaging of the retention structure includes joining an abutment structure of a complementary structure including the ramped portion of the retention structure with the retention structure during the joining of the halves of the mold cavity structure, wherein the injecting the thermoplastic material into the mold cavity further comprises overmolding the tubular structure and second tubular structure to form a connector fluidly connecting the tubular structure and the second tubular structure.

[0072] Aspect 8. The method of aspect 7, wherein the preloading the clamping tubular structure comprises sliding the retention structure in the X-direction toward the mold cavity structure.

[0073] Aspect 9. The method of aspect 8, wherein the sliding of the retention structure comprises compressing a spring in the retention structure against the mold cavity structure such that when the halves of the mold cavity separate, the spring returns the retention structure to a neutral position.

[0074] Aspect 10. The method of any one of aspects 7-9, wherein the connector comprises at least two connector portions, wherein each of the at least two connector portions extends from a center of the connector and has a first end connected to the center of the connector and a second open end connected to a second end of one of a plurality of tubes, and wherein each of the at least two connector portions is formed tapered, wherein an outer diameter of the first end at the center of the connector is greater than an outer diameter of the second end of the connector portion in a manner that the connector portion is flexible.

[0075] Aspect 11. The method of any one of aspects 7-10, wherein the core pin of the tubular structure has a geometry that corresponds to a geometry of an outer surface of the second tubular structure.

[0076] Aspect 12. The method of any one of aspects 7-11, wherein the preloading the core pin in the tubular structure against the second core pin comprises sliding the retention structure between 0.001 inches and 0.10 inches and preferably about 0.03 inches in the X-direction toward the mold cavity structure.

[0077] Aspect 13. A method comprising overmolding a polymeric connector onto two or more polymeric tubular structures by preloading forces on the two or more polymeric tubular structures each having an internal core pin to make the internal core pin not move in a first mold cavity, in conjunction with a second mold cavity and injection molding the connector.

[0078] Aspect 14. The method of aspect 13, wherein a diameter of the internal core pin receiving the preloaded force is less than a diameter of a body of the core pin such that the internal core pin does not displace from another internal core pin during the injection molding, and wherein the preloaded force is provided such that one of the two or more polymeric tubular structures is able to slide in an X direction toward the other internal core pin.

[0079] Aspect 15. The method of any of aspects 13-14, wherein the preloading the force includes clamping the tubular structures to a mold cavity structure in a Z direction and / or a containment direction using a retention structure, wherein the retention structure comprises a ramp.

[0080] Aspect 16. The method of aspect 15, wherein the preloading the force includes preloading the clamped tubular structures to provide a preloaded force on the clamped tubular structures in an X direction toward the mold cavity structure by engaging the retention structure during the conjunction of the first mold cavity and the second mold cavity.

[0081] Aspect 17. The method of aspect 16, wherein the preloading the clamped tubular structures includes sliding the retention structure in the X direction toward the first mold cavity and the second mold cavity.

[0082] The examples disclosed in this application are to be considered in all respects as illustrative and not restrictive. The scope of the application is indicated by the appended claims, rather than the foregoing description; and all changes that come within the meaning and range of equivalents of the claims are intended to be embraced therein.

Claims

1. A method for overmolding a tubular structure, comprising: inserting a core pin into the tubular structure such that at least a portion of a body of the core pin extends at least partially out of the tubular structure, wherein the core pin comprises the body and a flexible portion connected to the body and the flexible portion extends out of the tubular structure; clamping the tubular structure to a mold cavity structure in a Z direction and / or a container direction using a holding structure, wherein the holding structure comprises a ramped portion and the flexible portion extends out of the mold cavity structure; and injecting a thermoplastic material into a mold cavity of the mold cavity structure to overmold at least a portion of the tubular structure, wherein the injecting of the thermoplastic material includes the thermoplastic material contacting the portion of the core pin extending from the tubular structure.

2. The method of claim 1, wherein the flexible portion of the core pin is a wire or a flexible tube.

3. The method of claim 1, wherein the body of the core pin has a tapered structure and an indication on the body of the core pin, wherein the inserting of the core pin includes inserting the flexible portion of the core pin into the tubular structure and aligning an end of the tubular structure with the indication on the body of the core pin, and / or wherein the body includes a portion having a diameter that is less than a diameter of the body of the core pin, wherein the portion having the smaller diameter corresponds to a portion of the tubular structure in the holding structure.

4. The method of claim 1, further comprising removing the core pin from the tubular structure by engaging a flexible end of the core pin.

5. The method of claim 1, wherein the clamping of the tubular structure to the mold cavity structure includes deforming the tubular structure at least partially such that the tubular structure has an outer surface geometry that is different from an initial outer surface geometry of the tubular structure to insulate the clamped portion of the tubular structure from the injected thermoplastic material.

6. The method of claim 1, wherein an inner surface geometry of the portion of the holding structure that contacts an outer surface of the tubular structure is different from a molding surface geometry of the mold cavity adjacent to the holding structure.

7. The method of claim 1, further comprising: inserting a second core pin into a second tubular structure such that the core pin in the tubular structure abuts the second core pin in the second tubular structure to form an intersection point; preloading the clamped tubular structure to provide a preloading force on the clamped tubular structure in an X direction toward the mold cavity structure by engaging the holding structure during a joining of halves of the mold cavity structure such that the core pin in the tubular structure is preloaded against the second core pin and the core pin remains abutting to the second core pin during the injecting of the thermoplastic material, wherein the engaging of the holding structure includes joining abutting structures of complementary structures including the ramped portion of the holding structure to the holding structure during the joining of the halves of the mold cavity structure, ​ wherein the injecting the thermoplastic material into the mold cavity further comprises overmolding the tubular structure and a second tubular structure to form a connector fluidly connecting the tubular structure and the second tubular structure.

8. The method of claim 7, wherein the preloading the clamped tubular structure comprises sliding the retaining structure in the X direction toward the mold cavity structure.

9. The method of claim 8, wherein the sliding of the retaining structure comprises compressing springs in the retaining structure against the mold cavity structure such that when the halves of the mold cavity separate, the springs return the retaining structure to a neutral position.

10. The method of claim 7, wherein the connector comprises at least two connector portions, wherein each of the at least two connector portions extends from a center of the connector and has a first end connected to the center of the connector and a second open end connected to a second end of one of a plurality of tubes, and wherein each of the at least two connector portions is formed tapered, wherein an outer diameter of the first end at the center of the connector is greater than an outer diameter of the second end of the connector portion in a manner that gives the connector portion flexibility.

11. The method of claim 1, wherein the flexible portion of the core pin is a cable.

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