Method of molding composite objects

• US 7,118,697 B2
• Filed: 07/02/2002
• Issued: 10/10/2006
• Est. Priority Date: 07/02/2002
• Status: Expired due to Fees

• Current Assignee: ADC DSL Systems, Inc. (TE Connectivity Ltd. (United Kingdom))
• Original Assignee: ADC DSL Systems, Inc. (TE Connectivity Ltd. (United Kingdom))
• Inventors: Gustine, Gary, Sawyer, Michael
• Primary Examiner(s): Lee, Edmund H.
• Application Number:
  US10/189,369
• Publication Number:
  US 20040004306A1
• Time in Patent Office: 1,561 Days
• Field of Search: 264/279, 264/265, 264/273, 264/274, 264/275, 264/134, 264/247, 156/245
• US Class Current: 264/135
• CPC Class Codes: B29C 2045/14877 preheating or precooling the insert for non-deforming purposes
• CPC Class Codes: B29C 45/14311 using means for bonding the coating to the articles B29C45/14795 takes precedence
• CPC Class Codes: B29C 45/14778 the article consisting of a material with particular properties, e.g. porous, brittle
• CPC Class Codes: B29C 71/02 Thermal after-treatment B29C71/0063 and B29C71/0072 take precedence
• CPC Class Codes: B29K 2705/00 Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• CPC Class Codes: B29K 2705/02 Aluminium

Abstract

Methods for molding a surround over a liner to form a composite shell are provided. The liner is placed in a mold and molten surround material is injected into the mold so as to surround the liner. A surface of a protrusion of the liner abuts the mold so that the surface is exposed and is substantially flush with an exterior surface of the surround after the composite shell is removed from the mold. Molten surround material flows into a slot in a perimeter of the protrusion so that when the surround material solidifies, a rib of surround material extends into the slot to form a pressure seal between the liner and the surround. An adhesive is applied to the liner before placing the liner in the mold for reducing relative movement between the liner and surround as the surround material solidifies and the liner and surround cool.

Claims

1. A method for molding a composite object, the method comprising:

applying an adhesive to a first object of a first material;

curing the adhesive;

heating the first object with the cured adhesive thereon;

placing the heated first object in a mold so that a surface of a protrusion of the first object abuts an interior surface of the mold to prevent the surface of the protrusion from being covered by a second material to be injected into the mold in a molten state;

injecting the second material in the molten state into the mold so that the second material surrounds the first object to form the composite object, the second material flowing into a continuous slot around a perimeter of the protrusion of the first object so that when the second material solidifies, a rib of the second material extends into the continuous slot around the perimeter to form a pressure seal between the first object and the second material;

removing the composite object from the mold, wherein the protrusion of the first object extends through the second material so that the surface of the protrusion is substantially flush with an exterior surface of the second material; and

stabilizing the composite object until dimensions of the composite object stop changing.

2. The method of claim 1, wherein applying an adhesive to a first object comprises applying the adhesive to a heat conducting object.

3. The method of claim 1, wherein applying an adhesive to a first object comprises applying the adhesive to a metal object.

4. method of claim 3, wherein applying the adhesive to a metal object comprises applying the adhesive to an aluminum object.

5. The method of claim 1, wherein injecting the second material in the molten state into the mold comprises injecting a substantially non-heat conducting material in the molten state into the mold.

6. The method of claim 1, wherein injecting the second material in the molten state into the mold comprises injecting a plastic in the molten state into the mold.

7. The method of claim 1, wherein injecting the second material in the molten state into the mold comprises injecting glass-filled nylon in the molten state into the mold.

8. The method of claim 1, further comprising curing the second material after injecting the second material into the mold.

9. The method of claim 1, wherein curing the adhesive comprises curing the adhesive from about 6 hours to about 48 hours.

10. The method of claim 7, wherein heating the first object comprises heating the first object to a temperature ranging from about 110°

F. to about 160°

F.

11. The method of claim 7, wherein heating the first object comprises heating the first object to a temperature ranging from about 120°

F. to about 140°

F.

12. The method of claim 1, wherein stabilizing the composite object comprises placing the composite object in a substantially constant temperature environment.

13. The method of claim 7, wherein stabilizing the composite object comprises placing the composite object in a substantially constant temperature environment having a temperature ranging from about 65°

F. to about 85°

F.

14. The method of claim 1, wherein placing the first object in a mold comprises placing the first object in a mold having an internal surface temperature so that the second material has a resin-rich surface, whereby producing a relatively smooth, hard surface on the second material.

15. The method of claim 7, wherein placing the first object in a mold comprises placing the first object in a mold having an internal surface temperature within a range from about 170°

F. to about 180°

F.

16. The method of claim 1, wherein stabilizing the composite object comprises measuring the dimensions at a succession of times after removing the composite object from the mold.

17. The method of claim 1, wherein injecting the second material in the molten state into the mold comprises the second material flowing into a plurality of channels disposed in an exterior surface of the first object.

18. The method of claim 1, wherein injecting the second material in the molten state into the mold comprises the second material flowing into rectangular and semi-circular slots in the perimeter of the protrusion of the first object.

19. A method for molding a composite shell, the method comprising:

applying an adhesive to surfaces of a metal liner to be covered by a surround of the composite shell;

heating the metal liner with the adhesive thereon;

placing the heated metal liner in a mold so that a surface of a protrusion of the metal liner abuts an interior surface of the mold so that the surface of the protrusion remains uncovered by the surround;

injecting a plastic in a molten state into the mold so that the plastic surrounds the metal liner to form the surround and thereby the composite shell, the plastic flowing into a plurality of channels disposed in an exterior surface of the metal liner to reduce slippage and delamination between the metal liner and the surround when the plastic solidifies, the plastic flowing into a plurality of continuous slots around a perimeter of the protrusion so that when the plastic solidifies, a plurality of plastic ribs extend into the plurality of continuous slots around the perimeter to form a pressure seal between the metal liner and the surround;

removing the composite shell from the mold, wherein the protrusion of the liner extends through the surround so that the surface of the protrusion is substantially flush with an exterior surface of the surround; and

stabilizing the composite shell until dimensions of the composite shell stop changing.

20. The method of claim 19, further comprising curing the adhesive after applying the adhesive.

21. The method of claim 19, further comprising curing the plastic after injecting the plastic into the mold.

22. The method of claim 19, wherein stabilizing the composite shell comprises measuring the dimensions at a succession of times after removing the composite shell from the mold.

23. The method of claim 19, wherein injecting the plastic in the molten state into the mold comprises the plastic flowing into a plurality of continuous rectangular and semi-circular slots around the perimeter of the protrusion of the metal liner.

24. A method for molding a composite shell, the method comprising:

applying an adhesive to surfaces of a pair of aluminum liners to be covered by a surround of the composite shell;

heating the pair of aluminum liners with the adhesive thereon;

placing the heated pair of aluminum liners in a mold so that a surface of a protrusion of each of the pair of aluminum liners abuts an interior surface of the mold so that the surface of the protrusion remains uncovered by the surround;

injecting glass-filled nylon in a molten state into the mold so that the glass-filled nylon material surrounds the pair of aluminum liners to form the surround and thereby the composite shell, the glass-filled nylon flowing into a plurality of channels disposed in an exterior surface of each of the aluminum liners to reduce slippage and de-lamination between the aluminum liners and the surround when the glass-filled nylon solidifies, the glass-filled nylon flowing into a plurality of continuous slots around a perimeter of the protrusion so that when the glass-filled nylon solidifies, a plurality of glass-filled nylon ribs extend into the plurality of continuous slots around the perimeter to form a pressure seal between the metal liner and the surround;

removing the composite shell from the mold, wherein the protrusion of each of the pair of aluminum liners extends through the surround so that the surface of the protrusion is substantially flush with an exterior surface of the surround; and

stabilizing the composite shell until dimensions of the composite shell stop changing.

25. The method of claim 24, further comprising curing the glass-filled nylon from about three to four minutes after injecting the glass-filled nylon into the mold.

26. The method of claim 24, wherein curing the adhesive comprises curing the adhesive from about 6 hours to about 48 hours.

27. The method of claim 24, wherein heating the pair of aluminum liners comprises heating the pair of aluminum liners to a temperature ranging from about 110°

F. to about 160°

F.

28. The method of claim 24, wherein heating the pair of aluminum liners comprises heating the pair of aluminum liners to a temperature ranging from about 120°

F. to about 140°

F.

29. The method of claim 24, wherein stabilizing the composite shell comprises placing the composite shell in a substantially constant temperature environment having a temperature ranging from about 65°

F. to about 85°

F.

30. The method of claim 24, wherein stabilizing the composite takes at least 48 hours.

31. The method of claim 24, wherein placing the pair of aluminum liners in a mold comprises placing the pair of aluminum liners in a mold having an internal surface temperature within a range from about 170°

F. to about 180°

F.

32. The method of claim 24, wherein stabilizing the composite shell comprises measuring the dimensions at a succession of times after removing the composite shell from the mold.

33. A method for molding a composite shell, the method comprising:

applying an adhesive to surfaces of a metal liner to be covered by a surround of the composite shell;

heating the metal liner with the cured adhesive thereon;

placing the heated metal liner in a mold so that a surface of a protrusion of the metal liner abuts an interior surface of the mold so that the surface of the protrusion remains uncovered by the surround;

injecting a plastic in a molten state into the mold so that the plastic surrounds the metal liner to form the surround and thereby the composite shell, the plastic flowing into a plurality of channels disposed in an exterior surface of the metal liner to reduce slippage and de-lamination between the metal liner and the surround when the plastic solidifies, the plastic flowing into a plurality of continuous slots around a perimeter of the protrusion so that when the plastic solidifies, a plurality of plastic ribs extend into the plurality of continuous slots around the perimeter to form a pressure seal between the metal liner and the surround;

wherein heating the metal liner comprises heating the metal liner independent of injecting the plastic in a molten state into the mold so that the plastic surrounds the metal liner; and

stabilizing the composite shell until dimensions of the composite shell stop changing.

34. The method of claim 33, further comprising curing the adhesive after applying the adhesive.

35. The method of claim 33, further comprising curing the plastic after injecting the plastic into the mold.

36. The method of claim 33, wherein stabilizing the composite shell comprises measuring the dimensions at a succession of times after removing the composite shell from the mold.

37. The method of claim 33, wherein injecting the plastic in the molten state into the mold comprises the plastic flowing into a plurality of rectangular and semi-circular slots in the perimeter of the protrusion of the metal liner.

38. The method of claim 33, further comprising removing the composite shell from the mold, wherein the protrusion of the liner extends through the surround so that the surface of the protrusion is substantially flush with an exterior surface of the surround.

39. The method of claim 33, wherein the pressure seal formed between the metal liner and the surround is sealed against a pressure differential of about 15 psi.