Charge port assembly and molding method

Abstract

A charge port assembly for an electrified vehicle includes a housing having an opening and a first interchangeable seal removably received within the opening. A molding method for molding a charge port assembly includes injecting a first shot of material into a mold cavity to form a housing of the charge port assembly, positioning an insert within the mold cavity, and injecting a second shot of material into the mold cavity to form an interchangeable seal within the housing.

What is claimed is: 
     
         1 . A molding method, comprising:
 injecting a first shot of material into a mold cavity to form a housing of a charge port assembly;   positioning an insert within the mold cavity; and   injecting a second shot of material into the mold cavity to form an interchangeable seal within the housing.   
     
     
         2 . The molding method as recited in  claim 1 , wherein the first shot of material is a molten hard shot of plastic material. 
     
     
         3 . The molding method as recited in  claim 1 , wherein the second shot of material is a molten soft shot of plastic material. 
     
     
         4 . The molding method as recited in  claim 1 , comprising:
 removing the charge port assembly from the mold cavity after injecting the second shot of material.   
     
     
         5 . The molding method as recited in  claim 4 , comprising:
 injecting a third shot of material into the mold cavity to form a second housing of a second charge port assembly;   positioning a second insert within the mold cavity, the second insert having a different design than the insert; and   injecting a fourth shot of material into the mold cavity to form a second interchangeable seal within the second housing.   
     
     
         6 . The molding method as recited in  claim 5 , wherein the charge port assembly is configured to interface with a first style of an inlet charge coupler and the second charge port assembly is configured to interface with a second style of inlet charge coupler. 
     
     
         7 . The molding method as recited in  claim 5 , wherein the housing and the second housing include identical designs. 
     
     
         8 . The molding method as recited in  claim 1 , wherein the mold cavity is provided between a core side and a cavity side of a mold assembly. 
     
     
         9 . The molding method as recited in  claim 8 , comprising:
 after the first shot of material hardens, separating the core side from the housing;   manipulating the mold assembly into a position appropriate for injecting the second shot of material; and   positioning the insert within the mold cavity after manipulating the mold assembly into the position.   
     
     
         10 . The molding method as recited in  claim 1 , wherein the second shot of material hardens within an opening of the housing to form the interchangeable seal within the opening. 
     
     
         11 . A molding method, comprising:
 injection molding a first charge port assembly that includes a first housing and a first interchangeable seal in a first two-shot injection molding process; and   injection molding a second charge port assembly that includes a second housing and a second interchangeable seal in a second two-shot injection molding process,   wherein the first charge port assembly and the second charge port assembly are molded using a single set of molding tooling.   
     
     
         12 . The molding method as recited in  claim 11 , wherein the first charge port assembly is configured for use in a first global region and the second charge port assembly is configured for use in a second global region that is different from the first global region. 
     
     
         13 . The molding method as recited in  claim 11 , wherein the first two-shot injection molding process includes:
 injecting a first shot of material into a mold cavity to form the first housing;   positioning a first insert within the mold cavity; and   injecting a second shot of material into the mold cavity to form the first interchangeable seal within the first housing.   
     
     
         14 . The molding method as recited in  claim 13 , wherein the second two-shot injection molding process includes:
 injecting a third shot of material into the mold cavity to form the second housing;   positioning a second insert within the mold cavity, the second insert having a different design than the first insert; and   injecting a fourth shot of material into the mold cavity to form the second interchangeable seal within the second housing.   
     
     
         15 . The molding method as recited in  claim 14 , wherein the first housing and the second housing include identical designs.