Abstract:
An over-molded product, such as a container, and a method of manufacture. The product is primarily used for enclosing hazardous materials and is formed by utilizing a thermosetting plastic material in a reaction injection molding process at low temperature and pressure to envelop adjacent portions of two or more components to form the desired product. This provides a mechanical interface but avoids a chemical reaction which would degrade the components.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention relates to an over-molded product, that is, a product comprising multiple components fastened together by a molded outer material, and the method of manufacturing such a product.  
         PRIOR ART STATEMENT  
         [0002]    It is desirable to close and seal various products, such as containers having covers. Typical products are disclosed in the patents to Aske, Ser. No. 3,047,703; Kirchhan, Ser. No. 4,546,874; and Baerenwald, Ser. No. 5,794,814. Such containers may be utilized to safely enclose hazardous materials or to prevent leakage into the container. These are provided by using thermoplastic materials as closure systems.  
         SUMMARY OF THE INVENTION  
         [0003]    The product and method of the present invention provides for a new approach to the problem of forming seals for various products, such as containers for waste materials, which is extremely versatile and can be applied to such products for an unlimited number of industrial uses. the process utilizes a thermosetting plastic material primarily composed of a plural component liquid monomer mixture, which can be applied by a reaction injection molded (RIM) process to form an over-molded section around multiple components. The liquid plastic material is introduced into a mold which is positioned around the abutting and adjacent portions of the components at a low temperature and low pressure. A chemically driven exothermic reaction provides the energy necessary to facilitate polymerization of the liquid monomers. The process permits the formation of the over-molded sections in a large range of profile configurations and cross-sections, whether thick or thin. The components to be sealed may be made of plastic materials, composites or metals. A mechanical or physical interface is provided between the components and the over-molding material. The use of these liquid thermosetting plastic materials avoids problems which could exist if conventional injection molding were to be used, wherein it is necessary to melt solid plastic granules at temperatures between 400 and 600 degrees Fahrenheit, and then forcing the melt into mold cavities at pressures that normally run between 12,000 and 16,000 PSi. In such a process, the components to be joined would be seriously degraded. In this process, there is no chemical reaction, and thus a corresponding absence of chemical degradation of the components which would otherwise occur if the process involved molding at high temperatures and/or pressures. In addition, there is no loss of physical integrity, or degradation, such as would occur if high temperatures were involved, which would cause melting and re-solidifying of the components. The process can be utilized for such products as hazardous waste containers, high or low pressure protective containers, pressure vessels, drums, pipe joints, fastening systems, fascia, and the like. The result is a tamper-proof, weather-resistant product.  
           [0004]    It is, therefor, a principal object of the invention to form an over-molded product comprising multiple components secured by a thermosetting plastic material.  
           [0005]    It is another object to provide a mechanical interface between the components and the plastic material.  
           [0006]    It is a further object to apply a liquid plastic material at low temperatures and pressures to maintain the chemical and physical integrity of the components.  
           [0007]    These and other objects and features will be apparent from the embodiments described and shown below.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]    [0008]FIG. 1 is an exploded view of typical multiple components and their relation to mold members, prior to the molding step.  
         [0009]    [0009]FIG. 2 is a view in partial section, showing the multiple components within the mold members prior to the molding step.  
         [0010]    [0010]FIG. 3 is a view similar to FIG. 2, showing the components secured by the plastic molding material after the molding step.  
         [0011]    [0011]FIG. 4 is a view of the finished product manufactured by the previously shown steps.  
         [0012]    [0012]FIG. 5 is a view similar to FIG. 3 illustrating the formation of a similar product.  
         [0013]    [0013]FIG. 6 is a view of the finished product of FIG. 5.  
         [0014]    [0014]FIG. 7 is a view in section illustrating another product that can be made using the above shown process.  
         [0015]    [0015]FIG. 8 is view illustrating a further product similar to that of FIG. 7.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0016]    Referring now to the drawings, FIG. 1 is an exploded view of a typical arrangement of a mold comprising upper and lower mold members  11  and  12  typically formed of aluminum plates, having central openings  13  and  14  respectively. A typical container  15  is comprised of identical components  16  and  17 , shown as being generally cylindrical in configuration, although these could be round, oval, or any other desired shape. The container as shown is metal, but could be made of a plastic material, such as polyvinyl chloride or polyethylene, or a fiber-reinforced composite. The members have closed surfaces  18  and  19  and open surfaces  20  and  21 . The open surfaces have outwardly extending flanges  22  and  23  extending completely around the sides of the components. An inner container  25 , which contains the waste material (such as hazardous material) that is to be sealed within the container  15 , is arranged to be placed between the mold members so that it will be enclosed between the sealed components. A gasket  24 , made of a resilient polymeric material, is arranged between the mold members so that it will be utilized during the molding process, as explained below.  
         [0017]    The components  16  and  17  are placed together between the mold members as shown in FIG. 2 with the inner container within the components, and a gasket  24  is located and aligned between peripheral grooves  35  and  36  in the mold members. The gasket is formed in a triangular cross-section with an apex  33  and a flat base  34  as shown. A series of spaced openings  37  and  38  are located in the flanged portions  22  and  23  of the components for purposed described below. As shown in FIG. 3, the mold members are clamped together by any suitable means so that the inner surfaces  26  and  27  of the flanges are abutting. The components are held in place within the openings  13  and  14  of the mold members by placing the flanges within the offset portions  28  and  29  of the mold being configured so that openings  13  and  14  of the mold members extends completely around the flanges . The gasket  24  is compressed from its triangular shape to fit within the grooves  35  and  36 . The over-molding thermosetting plastic material is introduced into the mold openings to lock the flanges together; the material being introduced through an opening  30  in either mold member. In the illustrated arrangement the opening is in the upper surface of the upper mold member, but may be located elsewhere as convenient. The components  16  and  17  are now secured together by the over-molded material  32 . which has been injected into the mold via a hose  31  leading to a supply of the material. The material is now in the form of an outer solid mass of material  39  having a generally U-shaped configuration which envelops the flanges  22  and  23 . To provide further locking of the components, the material flows through the holes  37  and  38  in the mold members. It should be understood that the inner container  25  may be configured in other shapes necessary to retain the waste material being secured. It should be further understood that the outer container  15  need not be used to retain an inner container, but may be used in other ways; for example, the components  16  and  17  may be sent to a consumer who will place the waste material, such as effluent from a sewage system, directly in the lower component, then secure the upper component to the lower one in the manner described above, thus forming a complete container.  
         [0018]    The over-molding material is a thermosetting plastic, defined as a plastic material which undergoes a chemical change and hardens permanently when cured or heated in processing, and cannot be re-melted or re-processed. The thermosetting plastics used here are primarily composed of plural component liquid monomer mixtures. The preferred material is known as poly-dicyclo pentadiene, but other thermosetting materials, such as urethane or polyester may be used. The preferred material has a high impact resistance, and also exhibits stability in the presence of gamma radiation, making it particularly important ;when exposed to nuclear waste which the containers may enclose. If desired, other additives, such as colorants, fire retardants, or the like, may be added. While the novel process is similar to conventional reaction injection molding processes (RIM), it differs in that the material is injected at low temperatures, ranging from to 60 to 90 degrees Fahrenheit; and at low pressures below 40 pounds per square inch. This avoids physical and chemical degradation which would occur if higher temperatures and pressures were utilized as in conventional injection molding processes. In particular, it avoids the melting and re-solidifying of components made of a low melting point plastic under high temperatures. The process provides a strong mechanical interface between the components  16  and  17  and the material  32 . The completed container  15  is shown in FIG. 4. The monomers normally comprise an activator and a catalyst in equal proportions, which are mixed in a conventional mixing device before placing in the mold. FIGS. 5 and 6 depict a process and product similar to the container  15 , except that this product is in the form of a cylindrical drum  51  of the type commonly used in various industries. The drum has a circular cross-section, formed of a body  56  and a lid  57 . The body has a flange  59  extending completely around its upper open end, and a mating flange  58  extending completely around therearound. The lid has a cross-section equal to the cross-section of the body, and the flange of the lid sits against the flange of the body as shown. The mold members  52  and  53  are similar in design to the mold members  11  and  12  of the earlier described embodiment, and have openings  54  and  55  into which the over-molding material may be inserted. Seals  61  and  62  are inserted into the mold members as shown to provide extra sealing between the members. The over-molding plastic material  30  is introduced into the mold members in a manner and under the conditions described with respect to FIG. 3, and provides a molded segment  64  around the flanges to lock the lid and body together. similar to the locking described with respect to FIG. 3. Openings  62  and  63  are provided in a spaced peripheral arrangement in the flanges  58  and  59  so that the material may flow through the openings for extra locking, as with the FIG. 3 arrangement. The drum may be of any configuration useful in various industries. As is the case in the previously described embodiment, this drum may be used to enclose an inner container which holds the waste material, or my be sent to a customer who will place the waste material, such as sewage effluent, directly in the body  56  of the container, and then secure the lid  57  to the body in the manner described.  
         [0019]    [0019]FIG. 7 illustrates another use of the novel process, showing how this process may be used in conjunction with other products in addition to the containers illustrated above. The product shown is a pipe assembly designated by reference number  70 , and consists of identical fluid transmission pipe sections  71  having integral flanged ends  73  and  74  respectively. The flanged ends are placed within the cavities of mold members which are similar to the mold members described above with respect to the earlier forms of the invention, but specifically designed to fit the flanges. Spaced openings  77  and  78  are located peripherally within the flanged ends and aligned with each other, and the surfaces  75  and  76  of the flanges are abutted. Peripherally extending seals  79  and  80  are located in the abutting ends of the flanges for placement of a seal  80 , and the mold halves are clamped together. The thermosetting plastic material  32  is introduced in a manner and under the conditions described above, and flows into the mold openings and around the flanges and through the openings  79  and  80 . The result is an over molded member  81  which extends around the flanges  73  and  74  and the end portions of the pipes to provide a finished assembly  70 . FIG. 8 illustrates how the pipe sections  71  may be joined together to form a long multiple pipe assembly  72 , which may be provided in any length that is practical for shipping. The sections may be joined together as in FIG. 7 by over-molding each of the abutting sections by using a plurality of joints  81 . It is contemplated that although the pipes may be made of various materials, one particularly useful pipe material is di-cyclo pentadiene, the same material used as the over-molding material described herein. This material is highly corrosion resistant, and could conduct corrosive waste material with a minimum of corrosion.  
         [0020]    The products and processes shown and described above are merely exemplary. Other products and processes are considered to be within the scope of the invention.