Plastic and nonmetallic article shaping or treating: processes – Mechanical shaping or molding to form or reform shaped article – To produce composite – plural part or multilayered article
Reexamination Certificate
1999-09-07
2001-09-04
Silbaugh, Jan H. (Department: 1732)
Plastic and nonmetallic article shaping or treating: processes
Mechanical shaping or molding to form or reform shaped article
To produce composite, plural part or multilayered article
C264S273000, C264S274000, C264SDIG007
Reexamination Certificate
active
06284181
ABSTRACT:
BACKGROUND OF THE INVENTION
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
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
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.
It is, therefor, a principal object of the invention to form an over-molded product comprising multiple components secured by a thermosetting plastic material.
It is another object to provide a mechanical interface between the components and the plastic material.
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.
These and other objects and features will be apparent from the embodiments described and shown below.
REFERENCES:
patent: 2366274 (1945-01-01), Luth et al.
patent: 3047703 (1962-07-01), Aske
patent: 4304749 (1981-12-01), Bauer
patent: 4546874 (1985-10-01), Kirchhan
patent: 4826598 (1989-05-01), Cain
patent: 5794814 (1998-08-01), Baerenwald
patent: 5846468 (1998-12-01), Yagi et al.
Lee Edmund H.
Silbaugh Jan H.
Wolk Reuben
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