Over-molded product and method of manufacture

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.

I claim:  
     
         1 . A method of forming an over-molded product comprising multiple components without affecting the chemical and physical integrity of said components; comprising the steps of positioning a mold around said components, introducing a thermosetting plastic over-molding material under low pressure and low temperature conditions into said mold to provide a mechanical interface between said components and said plastic material, and forming said product without a chemical reaction and physical degradation within said components.  
     
     
         2 . The method of    claim 1    wherein said plastic material is poly-dicyclo pentadiene.  
     
     
         3 . The method of    claim 1    wherein said plastic material is urethane.  
     
     
         4 . The method of    claim 1    wherein said pressure is less than 40 pounds per square inch and said temperature is between 60 and 90 degrees Fahrenheit.  
     
     
         5 . The method of claim one wherein said step of introducing said plastic material into said mold member comprises reaction injection molding.  
     
     
         6 . The method of    claim 1    wherein said components each comprise outwardly extending members completely around said surfaces, comprising the further step of applying said plastic material around said members to interlock said components.  
     
     
         7 . The method of    claim 6    comprising the further step of passing said plastic material through a portion of said outwardly extending members.  
     
     
         8 . The method of    claim 1    wherein said components comprise fluid conveying pipes having abutting flanged ends, said step of introducing said over-molding material comprising applying said over-molding material around said flanged ends to interlock said ends.  
     
     
         9 . An over-molded product comprising multiple components and a thermosetting plastic over-molding material formed around at least a portion of said components, said over-molding material having a mechanical interface with said components without chemical reaction therewith, said components retaining their chemical and physical integrity during formation of said product.  
     
     
         10 . The product of    claim 9    wherein said over-molding material is poly-dicyclo pentadiene.  
     
     
         11 . The product of    claim 9    wherein said over-molding material is urethane.  
     
     
         12 . The product of    claim 9    wherein said over-molding material was formed at low temperature and low pressure.  
     
     
         13 . The product of    claim 9    wherein said over-molding material was-formed at a pressure of less than 40 pounds per square inch at a temperature between 60 and 90 degrees Fahrenheit.  
     
     
         14 . The product of    claim 9    wherein said components each include outwardly extending members extending completely around said components and said plastic material is formed around said members to interlock said components.  
     
     
         15 . The product of    claim 14    wherein said over-molding material also extends through a portion of said flanges.  
     
     
         16 . The product of    claim 9    wherein said components and said over-molding material form an outer container.  
     
     
         17 . The product of    claim 9    further comprising an inner container placed within said outer container.  
     
     
         18 . The product of    claim 9    wherein one of said components is a cylindrical container having a generally circular cross-section and having an open end with flanged members extending around the periphery thereof, the other of said components being a lid having similar flanged members around the periphery thereof and having a circular cross-section approximately equal to the cross-section of said container and fitting on said open end, said over-molding material contacting said flanged members of said open end of said container and of said lid to seal said container.  
     
     
         19 . The product of    claim 9    wherein said components comprise a plurality of fluid conveying pipes having abutting ends, said over-molding material enclosing said abutting ends to form at least one pipe joint.  
     
     
         20 . The product of    claim 19    wherein said pipes are formed of poly-dicyclo pentadiene.