U.S. patent application number 17/223089 was filed with the patent office on 2022-05-12 for method of forming a foldable or collapsible plastic and/or composite utility enclosure.
The applicant listed for this patent is Dustin Kyle Nolen, Raymond George Thompson. Invention is credited to Dustin Kyle Nolen, Raymond George Thompson.
Application Number | 20220145612 17/223089 |
Document ID | / |
Family ID | |
Filed Date | 2022-05-12 |
United States Patent
Application |
20220145612 |
Kind Code |
A1 |
Nolen; Dustin Kyle ; et
al. |
May 12, 2022 |
Method of Forming a Foldable or Collapsible Plastic and/or
Composite Utility Enclosure
Abstract
A method of forming and assembling a foldable plastic utility
enclosure using molds to form sides of the enclosure, preferably
using glass fiber-reinforced thermoplastic composite. The molds are
constructed to form a central hole in hinge members which are
formed on ends of the sides. The central hole of the hinge member
is molded with two molding parts, wherein one or both of the
molding parts have a solid central portion that forms the central
hole. The sides are removed from the molds after curing and the
sides are assembled to form the utility enclosure while the sides
are still hot from the molding process. Hinge pins are inserted
into the central holes of the hinge members to form hinges and to
prevent the sides from warping during cooling. Assembling the sides
and inserting hinge pins to form the utility enclosure is completed
within approximately 10 minutes after removing the sides from the
molds.
Inventors: |
Nolen; Dustin Kyle; (Mount
Olive, AL) ; Thompson; Raymond George; (Hoover,
AL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nolen; Dustin Kyle
Thompson; Raymond George |
Mount Olive
Hoover |
AL
AL |
US
US |
|
|
Appl. No.: |
17/223089 |
Filed: |
April 6, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16663391 |
Oct 25, 2019 |
11008134 |
|
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17223089 |
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62751278 |
Oct 26, 2018 |
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International
Class: |
E04B 1/343 20060101
E04B001/343; E04B 1/344 20060101 E04B001/344; B29C 70/54 20060101
B29C070/54 |
Claims
1. A method of forming a foldable plastic and/or composite
enclosure, wherein the foldable plastic and/or composite enclosure
comprises: a) a first side, a second side opposite the first side,
a third side, and a fourth side opposite the third side, each of
said sides having a first end and a second opposite end; and b) the
first end of the first side connected to the first end of the third
side by means of a first hinge; the second opposite end of the
second side connected to the second opposite end of the third side
by means of a second hinge; the second opposite end of the first
side connected to the second opposite end of the fourth side by
means of a third hinge; and the first end of the second side
connected to the first end of the fourth side by means of a fourth
hinge, wherein each end of each side has a plurality of
spaced-apart hinge members, wherein each hinge member has a central
hole, wherein each hinge is formed of the spaced-apart hinge
members, and wherein each hinge has a single hinge pin that extends
through the central holes of the spaced-apart hinge members that
form the hinge, the method comprising: a) providing molds to form
the first side, the second side, the third side, and the fourth
side, wherein the molds are constructed to form a central hole in
each hinge member; b) providing a material suitable for molding and
placing the material in molds to form the sides; c) removing the
sides from the molds after the curing of the material in the molds;
and d) assembling the sides to form the utility enclosure while the
sides are still hot from the molding process and inserting hinge
pins into the central holes of the spaced-apart hinge members to
form the hinges to prevent the sides from warping during cooling of
the utility enclosure.
2. The method of claim 1, further comprising molding the central
hole of the hinge member with two molding parts, wherein one
molding part or both molding parts have a solid central portion
that forms the central hole.
3. The method of claim 1, wherein assembling the sides and
inserting hinge pins is completed within approximately 10 minutes
of removing the sides from the molds.
4. The method of claim 1, wherein the material is a glass
fiber-reinforced composite.
5. The method of claim 1, wherein the material is
polypropylene.
6. The method of claim 1, wherein the material is a thermoplastic
polymer-graphene composite.
7. The method of claim 1, wherein the material is a polymer or a
composite.
8. A method of forming a foldable plastic and/or composite
enclosure, wherein the foldable plastic and/or composite enclosure
comprises: a) a first side, a second side opposite the first side,
a third side, and a fourth side opposite the third side, each of
said sides having a first end and a second opposite end; and b) the
first end of the first side connected to the first end of the third
side by means of a first hinge; the second opposite end of the
second side connected to the second opposite end of the third side
by means of a second hinge; the second opposite end of the first
side connected to the second opposite end of the fourth side by
means of a third hinge; and the first end of the second side
connected to the first end of the fourth side by means of a fourth
hinge, wherein each end of each side has a plurality of
spaced-apart hinge members, wherein each hinge member has a central
hole, wherein each hinge is formed of the spaced-apart hinge
members, and wherein each hinge has a single hinge pin that extends
through the central holes of the spaced-apart hinge members that
form the hinge, the method comprising: a) providing a mold or molds
to form the first side, the second side, the third side, and the
fourth side, wherein the mold or molds are constructed to form a
central hole in each hinge member; b) providing a plastic or
composite suitable for molding and placing the plastic or composite
in the mold or molds to form the sides; c) molding the central hole
of the hinge member with two molding parts, wherein one molding
part or both molding parts have a solid central portion that forms
the central hole; d) removing the sides from the molds after the
curing of the plastic in the molds; and e) assembling the sides to
form the utility enclosure while the sides are still hot from the
molding process and inserting hinge pins into the central holes of
the spaced-apart hinge members to form the hinges to prevent the
sides from warping during cooling of the utility enclosure.
9. The method of claim 8, wherein assembling the sides and
inserting hinge pins is completed within approximately 10 minutes
of removing the sides from the molds.
10. The method of claim 8, wherein the composite is a glass
fiber-reinforced thermoplastic composite.
11. The method of claim 10, wherein the thermoplastic is
polypropylene.
12. The method of claim 8, wherein the composite is a
polymer-graphene composite, and the polymer is a thermoplastic.
13. The method of claim 8, wherein the plastic is a polymer.
14. A method of forming a foldable plastic and/or composite
enclosure, wherein the foldable plastic and/or composite enclosure
comprises: a) a first side, a second side opposite the first side,
a third side, and a fourth side opposite the third side, each of
said sides having a first end and a second opposite end; and b) the
first end of the first side connected to the first end of the third
side by means of a first hinge; the second opposite end of the
second side connected to the second opposite end of the third side
by means of a second hinge; the second opposite end of the first
side connected to the second opposite end of the fourth side by
means of a third hinge; and the first end of the second side
connected to the first end of the fourth side by means of a fourth
hinge, wherein each end of each side has a plurality of
spaced-apart hinge members, wherein each hinge member has a central
hole, wherein each hinge is formed of the spaced-apart hinge
members, and wherein each hinge has a single hinge pin that extends
through the central holes of the spaced-apart hinge members that
form the hinge, the method comprising: a) providing molds to form
the first side, the second side, the third side, and the fourth
side, wherein the molds are constructed to form a central hole in
each hinge member; b) providing a plastic or composite suitable for
molding and placing the plastic or composite in molds to form the
sides; c) molding the central hole of the hinge member with two
molding parts, wherein one molding part or both molding parts have
a solid central portion that forms the central hole; d) removing
the sides from the molds after the curing of the plastic in the
molds; and e) assembling the sides to form the utility enclosure
while the sides are still hot from the molding process and
inserting hinge pins into the central holes of the spaced-apart
hinge members to form the hinges to prevent the sides from warping
during cooling of the utility enclosure, wherein assembling the
sides and inserting hinge pins is completed within approximately 10
minutes of removing the sides from the molds.
15. The method of claim 14, wherein the composite is a glass
fiber-reinforced thermoplastic composite.
16. The method of claim 15, wherein the thermoplastic is
polypropylene.
17. The method of claim 14, wherein the composite is a
polymer-graphene composite and the polymer is a thermoplastic.
18. The method of claim 14, wherein the plastic is a polymer.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation in part of U.S. patent
application Ser. No. 16/663,391, filed on Oct. 25, 2019, the
contents of that application being incorporated herein by reference
in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to underground utility enclosures for
providing protection for below ground devices such as water meters,
valves, telecom hardware, and the like and, more particularly, to a
foldable and/or collapsible plastic/composite utility
enclosure.
BACKGROUND OF THE INVENTION
[0003] Utility enclosures are used to protect buried meters,
valves, and telecom hardware and need to be capable of withstanding
heavy loads that may be placed on the cover of the utility
enclosure. Concrete utility enclosures are commonly used in or near
roadways and driveways since they are heavy duty and are capable of
withstanding heavy loads placed on the cover. Concrete utility
enclosures are formed by a wall of concrete that extends around the
utility. A lip extends about the top of the utility enclosure in
the interior of the utility enclosure. The cover of the utility
enclosure fits into the interior of the utility enclosure and rests
on the lip. The concrete lip provides sufficient support to the
cover to enable the utility enclosure to withstand the force of
heavy loads.
[0004] Concrete utility enclosures present some disadvantages,
however. Concrete utility enclosures are difficult to transport and
install. They are bulky and take up space. During transport,
concrete utility enclosures are prone to being chipped, and
significant amounts of concrete utility enclosures become
non-usable because of damage incurred in transport. Installation of
concrete utility enclosures is difficult because of the weight of
the utility enclosures. Installation of a concrete utility
enclosure generally requires the effort of two people because the
utility enclosures weigh in excess of two hundred pounds each. The
weight of the concrete utility enclosures also presents some danger
of physical injury to the persons installing the utility
enclosure.
[0005] Plastic utility enclosures are known. U.S. Pat. No.
5,333,750 discloses a plastic utility enclosure that is durable,
lightweight, and capable of being located in roadways or driveways
and withstanding heavy loads. However, plastic utility enclosures
also are bulky and take up space during transportation. What is
needed is a foldable utility enclosure that takes up reduced space
when folded.
SUMMARY OF THE INVENTION
[0006] This invention is a foldable plastic/composite utility
enclosure having a first side, a second side opposite the first
side, a third side, and a fourth side opposite the third side. Each
of the sides has a first end and a second opposite end. The first
end of the first side is connected to the first end of the third
side by means of a first hinge. The second opposite end of the
second side is connected to the second opposite end of the third
side by means of a second hinge. The second opposite end of the
first side is connected to the second opposite end of the fourth
side by means of a third hinge. The first end of the second side is
connected to the first end of the fourth side by means of a fourth
hinge.
[0007] The third side is constructed to rotate on the first and
second hinges only away from the first side. The fourth side is
constructed to rotate on the third and fourth hinges only towards
the first side. The third side and the fourth side are constructed
to rotate until the first side engages the second side and the
foldable plastic/composite utility enclosure is in a folded
configuration. The folded plastic/composite utility enclosure when
in a folded configuration has only 15 to 20 percent of the
thickness compared to an unfolded configuration.
[0008] The first end of the first side and the first end of the
second side are curved. The first end of the third side is
positioned slideably over the first end of the first side and the
first end of the fourth side is positioned slideably over the first
end of the second side. The second opposite end of the first side
abuts against the second opposite end of the fourth side and the
second opposite end of the third side abuts against the second
opposite end of the second side. The second opposite ends are
angled.
[0009] Each end of each side has spaced-apart hinge members. Each
hinge member has a central hole. Each hinge is formed of the hinge
members and each hinge has a single hinge pin that extends through
the central holes of the hinge members that form the hinge. Each
hinge member is positioned in a housing. The housing has an open
interior to help anchor the housing in the ground. Each edge of
each side has a plurality of spaced-apart hinge members wherein
hinge members on one side engage the hinge members on another side
to form the hinge. One or more of the hinges may have a reversibly
insertable locking pin that prevents the sides from rotating on the
hinges and prevents the foldable plastic/composite utility
enclosure from folding.
[0010] The foldable and/or collapsible plastic/composite utility
enclosure of this invention can be made of any type of plastic or
composite, preferably plastic imbedded with fibers such as carbon
fibers, glass fibers, or ceramic fibers or imbedded with particles
such as glass particles. The use of plastic/composite and various
openings or cutouts makes the utility enclosure light weight. The
hinges allow the utility enclosure to be folded flat for storage
and transportation. The pairs of sides are symmetrical which
facilitates manufacturing. The foldable plastic/composite utility
enclosure is ideal for housing underground utilities. However, it
can be used to house or contain any desired device.
[0011] The present invention provides of method of forming and
assembling the foldable plastic and/or composite utility enclosure.
Molds are provided to form the first side, the second side, the
third side, and the fourth side. The molds are constructed to form
a central hole in each hinge member. Material including plastic or
composite suitable for molding is placed in the molds to form the
sides. The central hole of the hinge member is molded with two
molding parts, wherein one or both of the molding parts have a
solid central portion that forms the central hole. The sides are
removed from the molds after the curing of the plastic in the
molds. The sides are assembled to form the utility enclosure while
the sides are still hot from the molding process and the hinge pins
are inserted into the central holes of the hinge members to form
the hinges to prevent the sides from warping during cooling.
Assembling the sides and inserting hinge pins to form the utility
enclosure is completed within approximately 10 minutes after
removing the sides from the molds. The plastic used to form the
sides is, preferably, a glass fiber-reinforced thermoplastic. The
thermoplastic is, preferably, polypropylene.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a top, front, perspective view of the utility
enclosure of the present invention.
[0013] FIG. 2A is perspective view from an exterior surface of a
first side the utility enclosure.
[0014] FIG. 2B is a perspective view from an interior surface of
the first side.
[0015] FIG. 3A is perspective view from an exterior surface of a
third side.
[0016] FIG. 3B is a perspective view from an interior surface of
the third side.
[0017] FIG. 4 is a top, interior surface view of the second side of
the utility enclosure.
[0018] FIG. 5 is a top, interior surface view of the third side of
the utility enclosure.
[0019] FIG. 6 is a top, exterior surface view of the first side of
the utility enclosure.
[0020] FIG. 7A is a top perspective view of the utility enclosure
laying with its first side on a horizontal plane in an unfolded
configuration.
[0021] FIG. 7B shows the utility enclosure of FIG. 7A in a
semi-folded configuration.
[0022] FIG. 7C shows the utility enclosure of FIG. 7A in a
completely folded configuration.
[0023] FIG. 8A shows an enlarged top view of an end of a second
side and an end of the third side in an unfolded configuration.
[0024] FIG. 8B show an enlarged top view of the end of the second
side and an end of a fourth side in an unfolded configuration.
[0025] FIGS. 9A and 9B show the same views as 8A and 8B but with
the utility utility enclosure in a semi-folded configuration.
[0026] FIGS. 10A and 10B show the same views 8A and 8B but with the
utility enclosure in a completely folded configuration.
[0027] FIG. 11 shows a top perspective view of the utility
enclosure with a top cover inserted in a top end of the utility
enclosure.
[0028] FIG. 12 shows a top perspective view of the top cover having
an opening with a door.
[0029] FIG. 13 shows a bottom perspective view of the utility
enclosure with a bottom cover attached reversibly to a bottom end
of the utility enclosure.
[0030] FIG. 14 shows a perspective view of corner with a hinge
connecting two sides, with a locking pin inserted through the hinge
members to prevent rotation of the sides on the hinge and to
prevent folding of the foldable plastic utility enclosure.
[0031] FIG. 15 shows two molding parts which form the hinge member
and form a central hole in the hinge member when a side is being
formed in a molding process.
DETAILED DESCRIPTION OF THE INVENTION
[0032] While the following description details the preferred
embodiments of the present invention, it is to be understood that
the invention is not limited in its application to the details of
arrangement of the parts or the illustrations disclosed herein,
since the invention is capable of other embodiments and of being
practiced in various ways.
[0033] FIG. 1 is a top, front, perspective view of the utility
enclosure 10 of the present invention. The utility enclosure 10 is
rectangular and has a first side 11, a second side 12 opposite the
first side 11, a third side 13, and a fourth side 14 opposite the
third side 13. The first side 11 and the second side 12 form a
first pair of sides and the third side 13 and the second side 14
form a second pair of sides. The utility enclosure 10 has a top end
15, a bottom end 16, and an interior 17. An interior ledge 18 is
formed on each side in the interior 17 near the top end 15 to
support a cover (see FIGS. 11 and 12). The edges of each side 11,
12, 13, and 14 are joined together with hinges 20, 21, 22, and 23
to form the rectangular utility enclosure 10, with a hinge in each
corner of the rectangle. The hinges 20, 21, 22, and 23 are made up
of hinge members 24. Each hinge member 24 has a central hole 25
(see FIGS. 2A and 2B) for the insertion of a hinge pin 26 to form
the hinge, as is known in the art. The hinge members 24 are formed
in open hollow housings 27, the housings 27 having interiors
28.
[0034] First side 11 has a first end 30 and a second opposite end
31. The second side 12 has a first end 32 and a second opposite end
33. The third side 13 has a first end 34 and a second opposite end
35. The fourth side 14 has a first end 36 and a second opposite end
37. The first ends 30 and 32 of the sides 11 and 12 (first pair of
sides) form curved corners which end with curved extensions 38. The
second opposite ends 31 and 33 of sides 11 and 12 are also curved
and form acute angles 39. The first ends 34 and 36 of sides 13 and
14 (second pair of sides) and the second opposite ends 35 and 37 of
sides 13 and 14 form obtuse angles 40. The first ends 34 and 36 of
the sides 13 and 14 fit over the curved extensions 38 of sides 11
and 12 and the first ends 34 and 36 may be slightly curved to match
the curved extensions 38. The second opposite end 35 of the third
side 13 forms an obtuse angle 40 between an interior surface 45
(see FIG. 3B) of the third side 13 and an interior surface 42 (see
FIG. 2B) of the first side 11. The obtuse angle 40 extends from the
top end 15 of the utility enclosure 10 to the bottom end 16 of the
utility enclosure 10. The second opposite end 37 of the fourth side
14 forms an acute angle 39 between an interior surface 45A of the
fourth side 14 and an interior surface 42 of the first side 11 and
the acute angle 39 extends from the top end 15 of the utility
enclosure 10 to the bottom end 16 of the utility enclosure 10. The
angled edges of the second opposite ends 35 and 37 of sides 13 and
14 abut the angled edges of the ends 31 and 33 of the sides 11 and
12. The sides 11, 12, 13, and 14 may have openings 19 to
accommodate wires, pipes, tubing, and the like.
[0035] FIG. 2A is perspective view from an exterior surface 41 of
the first side 11, separated from the utility enclosure 10, and
FIG. 2B is a perspective view from an interior surface 42 of the
first side 11. The hinge members 24, the housings 27, and the
interiors 28 can be seen in more detail. Grooves or spaces 43
between the hinge members 24 accommodate the housings 27 of the
hinge members 24 that engage the first side 11 to complete the
formation of the hinges 23.
[0036] FIG. 3A is perspective view from an exterior surface 44 of
the third side 13 separated from the utility enclosure 10 and FIG.
3B is a perspective view from an interior surface 45. The hinge
members 24, the housings 27, and the interiors 28 can be seen in
more detail. FIGS. 3A and 3B further show latches 46 which lock the
third side 13 to the first side 11 to prevent the utility enclosure
10 from folding. Grooves 47 between the hinge members 24
accommodate the housings 27 of the hinge members 24 that engage the
third side 13 to complete the formation of the hinges 20, 21, 22,
23.
[0037] The housings 27 strengthen the hinges 20, 21, 22, 23 and
protect them from external forces. When the utility enclosure 10 is
placed in the ground to protect an underground device, soil, rocks,
and cement can fill the interiors 28 of the housings 27 which will
prevent the utility enclosure 10 from moving or folding. The first
side 11 and the second side 12 are identical to each other and the
third side 13 and the fourth side 14 are identical to each other,
including with regard to hinging and folding features.
[0038] FIG. 4 is a top, interior surface view of the second side
12. FIG. 5 is a top, interior surface view of the third side 13.
FIG. 6 is a top, exterior surface view of the first side 11. The
utility enclosure 10 is formed by inserting the housings 27 on end
35 of the third side 13 in between the housings 27 on end 31 of the
second side 12 and inserting the housings 27 on end 34 of the third
side 13 in between the housings 27 on end 30 of the first side 11.
The pins 26 are then inserted through the holes 25 to form the
hinges 20, 21, 22, 23. The fourth side 14 is added to sides 11 and
12 in the same way to complete the assembly of the utility
enclosure 10.
[0039] FIG. 7A is a top perspective view of the utility enclosure
10 laying with its first side 11 on a horizontal plane, shown by
double arrow 50. The utility enclosure 10 is in an unfolded
configuration. FIG. 7B shows the utility enclosure 10 in a
semi-folded configuration. FIG. 7C shows the utility enclosure 10
in a completely folded configuration. As the second side 13 is
rotated away from the first side 11 the fourth side 14 is rotated
towards the first side 11. The second side 12 moves inward towards
the first side 11. In the folded configuration the utility
enclosure 10 has about 15% to 25% of the thickness, compared to the
unfolded configuration, preferably about 20%.
[0040] FIG. 8A shows an enlarged top view of the end 33 of the
second side 12 and the end 35 of the third side 13 in an unfolded
configuration. FIG. 8B shows an enlarged top view of the end 32 of
the second side 12 and the end 36 of the fourth side 14 in an
unfolded position. The utility enclosure 10 cannot fold in a
direction opposite to that shown in FIGS. 9A, 9B, 10A, and 10C
because the end 35 of side 13 abuts the end 33 of side 12, shown by
arrow 51, at an angle relative to sides 12 and 13. The end 35 of
side 13 cannot move around the end 33 of side 12. However, the end
36 of side 14 can move around end 32 of side 12, as shown in FIGS.
9A, 9B, 10A, and 10C, because end 36 overlaps end 32, shown by
arrow 52.
[0041] FIGS. 9A and 9B show the same views as FIGS. 8A and 8B but
with the utility enclosure 10 in a semi-folded configuration. Arrow
53 in FIG. 9A shows the extent to which end 35 of side 13 has moved
away from end 33 of side 12. Arrow 54 in FIG. 9B shows the extent
to which end 36 of side 14 has moved over and around the curved
extension 38 of end 32 of side 12. FIGS. 10A and 10B show the same
views as FIGS. 8A and 8B but with the utility enclosure 10 in a
completely folded configuration with the first side 11 engaging the
second side 12. The folding of the utility enclosure 10 is
reversible and the utility enclosure 10 can be restored to its
unfolded configuration by pulling the first side 11 and the second
side 12 apart.
[0042] FIG. 11 shows a top perspective view of the utility
enclosure 10 with a top cover 60 inserted in the top end 15. The
top cover 60 can have handles or openings for removing the cover
60. FIG. 12 shows a top perspective view of a top cover 61 having
an opening 62 with a door 63. The interior 17 of the utility
enclosure 10 can be viewed and accessed by raising the door 63.
[0043] FIG. 13 shows a bottom perspective view of the utility
enclosure 10 with a bottom cover 64 attached reversibly to the
bottom end 16 by methods known in the art. The use of a bottom
cover 64 allows the utility enclosure 10 to be used as any type of
utility enclosure for any type of articles.
[0044] FIG. 14 shows a perspective view of corner with a hinge
connecting two sides, with a locking pin 70 inserted through the
hinge members 24 to prevent rotation of the sides on the hinge and
to prevent folding of the foldable plastic/composite utility
enclosure. An insertion hole 71 is on the top end 15 to insert the
locking pin 70. Each hinge member 24 has an upper groove 72 and a
bottom groove 73 through which the locking pin 70 passes. The
locking pin 70 can be retained in an opening 74 in the bottom hinge
member.
[0045] The sides 11, 12, 13, and 14 of the utility enclosure 10 are
formed separately in molds. The plastic material forming the side
hardens in the mold within a few minutes. The side is hot when it
comes out of the mold and the temperature of the side can range
from 180 to in excess of 250 degrees F. The outer surface of the
side is hardened but the interior part of the side can still be
molten. In a standard procedure, each side is removed from the mold
and allowed to cool. As the side begins to cool it will start to
warp immediately which renders the side useless. To prevent warping
of the side, the side may be placed in a cooling rack immediately
after it comes out of the mold. The cooling rack holds the side in
a fixed configuration until the internal plastic is solidified and
the temperature has cooled below 180 degrees F. The cooling rack
prevents the side from warping but the side has to remain in the
cooling rack for up to 60 minutes. This amount of time makes the
manufacturing process impractical.
[0046] Another problem arises when drilling a central hole 25 in
the hinge member 24 for insertion of a hinge pin 26. Since the
hinge members are made of glass-reinforced thermoplastic the time
required to drill the central hole in the hinge member is up to 20
minutes. In addition, the drill bit wears out after three or four
holes are drilled. This amount of time and wearing out of the drill
bit also makes the manufacturing process impractical.
[0047] In order to overcome these manufacturing problems, the mold
was designed to form the central hole in the hinge member during
the molding process of the side. FIG. 15 shows two molding parts
101 and 102 of a mold 100, wherein the two molding parts 101 and
102 form the hinge member. Part 101 has a solid central portion 103
that forms the central hole in the hinge member. Likewise, part 102
has a solid central portion 104 that forms the central hole in the
hinge member. The combination of central holes, formed by part 101
and part 102 and extended across the plurality of spaced apart
hinge members, forms the hinge. With the hinge member reduced in
mass, the cooling time in the mold is reduced. At the end of curing
in the molds, the sides are removed from the molds with the central
hole formed in the hinge member. The utility enclosure can be
assembled with the hinge pins inserted in the central holes of the
hinge members, within about 10 minutes after removing the sides
from the molds. Assembling the utility enclosure and inserting the
hinge pins in the hinge members while the sides are still hot from
the molding process surprisingly prevent the sides from warping
during cooling. In addition, the utility enclosures can be allowed
to cool in the folded configuration to facilitate shipping or
storage.
[0048] The material used to form the sides can be any polymer or
any composite, preferably a glass fiber-reinforced thermoplastic or
a thermoplastic polymer-graphene composite. The thermoplastic is,
preferably, polypropylene. Glass fiber-reinforced polypropylene has
improved dimensional stability, reduced warpage, increased
rigidity, and increased strength. Heat deflection temperature at
264 psi is increased up to 300.degree. F. (150.degree. C.) for 40%
glass fiber reinforced polypropylene. Polypropylene's coefficient
of thermal expansion is cut in half with 40% glass reinforcement.
Glass fiber-reinforced polypropylene has good impact strength, very
good mold filling capability, excellent stiffness, good dimensional
stability, and low creep under load at elevated temperatures (RTP
Company, Winona, Minn.).
[0049] The foregoing description illustrates and describes the
disclosure. Additionally, the disclosure shows and describes only
the preferred embodiments but, it is to be understood that the
preferred embodiments are capable of being formed in various other
combinations, modifications, and environments and are capable of
changes or modifications within the scope of the invention concepts
as expressed herein, commensurate with the above teachings and/or
the skill or knowledge of the relevant art. The embodiments
described herein above are further intended to explain the best
modes known by applicant and to enable others skilled in the art to
utilize the disclosure in such, or other, embodiments and with the
various modifications required by the particular applications or
uses thereof. Accordingly, the description is not intended to limit
the invention to the form disclosed herein. Also, it is intended
that the appended claims be construed to include alternative
embodiments. It will be further understood that various changes in
the details, materials, and arrangements of the parts which have
been described and illustrated above in order to explain the nature
of this invention may be made by those skilled in the art without
departing from the principle and scope of the invention as recited
in the following claims.
* * * * *