METHOD FOR FORMING A FOLDABLE AND / OR DETACHABLE PLASTIC / COMPOSITE UTILITY CABINET

Abstract

A method for forming and assembling a collapsible plastic utility cabinet using molds to form the cabinet sides, preferably using a glass fiber reinforced thermoplastic composite. The molds are constructed to form a center hole in hinge members formed at the ends of the sides. The center hole of the hinge member is molded with two molding parts, wherein one or both molding parts have a solid center portion forming the center hole. The sides are removed from the molds after curing and assembled to form the utility cabinet while still warm from the molding process. Hinge pins are inserted into the center holes of the hinge members to form hinges and prevent the sides from warping during cooling.The assembly of the sides and the insertion of hinge pins to form the utility cabinet is completed approximately 10 minutes after removing the sides from the molds.

Description

METHOD FOR FORMING A FOLDABLE AND / OR DETACHABLE PLASTIC / COMPOSITE UTILITY CABINET Field of Invention The invention relates to underground utility cabinets for providing protection to underground devices such as water meters, valves, telecommunications hardware and the like, and more particularly to a foldable and / or detachable plastic / composite utility cabinet. Background of the Invention Utility cabinets are used to protect buried meters, valves, and telecommunications hardware and must be able to withstand heavy loads that may be placed on the cabinet cover. Concrete utility cabinets are commonly used in or near roads and access points because they are strong and capable of supporting heavy loads placed on the cover. Concrete utility cabinets consist of a concrete wall that extends around the utility. A flange extends around the top of the utility cabinet on the inside. The utility cabinet cover fits inside the utility cabinet. Ref. 350664 rests on the flange. The concrete flange provides sufficient support to the cover to allow the utility cabinet to withstand the force of heavy loads. However, concrete utility cabinets have some disadvantages. They are difficult to transport and install. They are bulky and take up space. During transport, concrete utility cabinets are prone to chipping, and significant quantities are rendered unusable due to shipping damage. Installing concrete utility cabinets is difficult because of their weight. Installing a concrete utility cabinet typically requires two people because they weigh over 200 pounds each. The weight of concrete utility cabinets also presents a risk of physical injury to the installers. Plastic utility cabinets are known; U.S. Patent No. 5,333,750 describes a durable, lightweight plastic utility cabinet capable of being placed on roadways or driveways and supporting heavy loads. However, plastic utility cabinets are also bulky and take up space during transport. What is needed is a collapsible utility cabinet that occupies minimal space when folded. Summary of the Invention This invention is a collapsible plastic / composite utility cabinet having a first side, a second side opposite the first side, a third side, and a fourth side opposite the third side. Each side 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. The third side is designed to pivot on the first and second hinges only away from the first side. The fourth side is designed to pivot on the third and fourth hinges only toward the first side. The third and fourth sides are designed to pivot until the first side engages with the second side, and the 71 in / eznz / e / GALA collapsible plastic / composite utility cabinet is in a folded configuration. The folded plastic / composite utility cabinet, when in a folded configuration, is only 15 to 20 percent thick compared to an unfolded configuration. The first end of the first side and the first end of the second side are curved. The first end of the third side slides over the first end of the first side, and the first end of the fourth side slides over the first end of the second side. The second opposite end of the first side abuts the second opposite end of the fourth side, and the second opposite end of the third side abuts the second opposite end of the second side. The second opposite ends are angled. Each end of each side has spaced hinge members. Each hinge member has a center hole. Each hinge is formed by the hinge members, and each hinge has a single hinge pin that extends through the center holes of the hinge members that form the hinge. Each hinge member is housed in a casing. The casing has an open interior to help anchor the casing to the floor. Each edge of each side has a plurality of spaced hinge members in which the hinge members on one side engage with the hinge members on the other 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 plastic / composite folding service cabinet from bending. The collapsible and / or demountable plastic / composite utility cabinet of this invention can be made of any type of plastic or composite, preferably plastic embedded with fibers such as carbon fibers, glass fibers, or ceramic fibers, or embedded with particles such as glass particles. The use of plastic / composite and various openings or cutouts makes the utility cabinet lightweight. Hinges allow the utility cabinet to be folded for storage and transport. The pairs of sides are symmetrical, which facilitates manufacturing. The collapsible plastic / composite utility cabinet is ideal for housing underground utilities. However, it can be used to house or contain any desired device. The present invention provides a method for forming and assembling a collapsible utility cabinet made of plastic and / or composite. Molds are provided for forming the first, second, third, and fourth sides. The molds are constructed to form a central hole in each hinge member. Material, including plastic or a suitable composite, 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 molding parts have a solid central portion that forms the central hole. The sides are removed from the molds after the plastic has cured in the molds.The sides are assembled to form the utility cabinet while they are still warm from the molding process, and hinge pins are inserted into the center holes of the hinge members to form the hinges and prevent the sides from warping during cooling. The assembly of the sides and the insertion of hinge pins to form the utility cabinet are completed approximately 10 minutes after the sides are removed from the molds. The plastic used to form the sides is preferably a fiberglass-reinforced thermoplastic, preferably polypropylene. Brief Description of the Figures FIG. 1 is a top front perspective view of the utility cabinet of the present invention. FIG. 2A is a perspective view from an exterior surface of a first side of the cabinet for public services. FIG. 2B is a perspective view from an interior surface of the first side. FIG. 3A is a perspective view from an exterior surface of a third side. FIG. 3B is a perspective view from an interior surface of the third side. FIG. 4 is a top view of the interior surface of the second side of the utility cabinet. FIG. 5 is a top view of the interior surface of the third side of the utility cabinet. FIG. 6 is a top view of the outer surface of the first side of the utility cabinet. FIG. 7A is a top perspective view of the utility cabinet placed with its first side in a horizontal plane in an unfolded configuration. FIG. 7B shows the utility cabinet of FIG. 7A in a semi-folded configuration. FIG. 7C shows the utility cabinet of FIG. 7A in a fully folded configuration. FIG. 8A shows an enlarged top view of one end of a second side and one end of a third side in an unfolded configuration. FIG. 8B shows an enlarged top view of the second side end and a fourth side end in an unfolded configuration. FIGS. 9A and 9B show the same views as figures 8A and 8B but with the utility cabinet in a semi-folded configuration. Figures 10A and 10B show the same views as Figures 8A and 8B but with the utility cabinet in a fully folded configuration. FIG. 11 shows a top perspective view of the utility cabinet with a top cover inserted at one upper end of the utility cabinet. FIG. 12 shows a top perspective view of the top deck which has an opening with a door. FIG. 13 shows a bottom perspective view of the utility cabinet with a bottom cover reversibly attached to a lower end of the utility cabinet. FIG. 14 shows a perspective view of a corner with a hinge connecting two sides, with a locking bolt inserted through the hinge members to prevent rotation of the hinge sides and to prevent folding of the foldable utility plastic cabinet. FIG. 15 shows two molding parts that form the hinge member and form a central hole in the hinge member when one side is being formed in a molding process. Detailed Description of the Invention Although the following description details preferred embodiments of the present invention, it should be understood that the invention is not limited in its application to the details of the arrangement of the parts or the illustrations described herein, since the invention is capable of other embodiments and can be practiced in various ways. Figure 1 is a top front perspective view of the utility cabinet 10 of the present invention. The utility cabinet 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 the first pair of sides, and the third side 13 and the second side 14 form the second pair of sides. The utility cabinet 10 has an upper end 15, a lower end 16, and an interior 17. An interior rim 18 is formed on each side in the interior 17 near the upper end 15 to support a cover (see Figures in yiin / eznz / e / γΐΛΐ and 12). The edges on each side 11, 12, 13, and 14 are joined with hinges 20, 21, 22, and 23 to form the rectangular service cabinet 10, with one hinge at each corner of the rectangle. The hinges 20, 21, 22, and 23 are formed by hinge members 24.Each hinge member 24 has a central hole 25 (see Figures 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 housing 27 having internals 28. The first side 11 has a first endpoint 30 and an opposite second endpoint 31. The second side 12 has a first endpoint 32 and an opposite second endpoint 33. The third side 13 has a first endpoint 34 and an opposite second endpoint 35. The fourth side 14 has a first endpoint 36 and an opposite second endpoint 37. The first ends 30 and 32 of sides 11 and 12 (first pair of sides) form curved corners that terminate in curved extensions 38. The opposite second 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 opposite second ends 35 and 37 of sides 13 and 14 form obtuse angles 40. The first ends 34 and 36 of sides 13 and 14 fit together on the curved extensions 38 of sides 11 and 12 and the first ends 34 and 36 may in yiin / eznz / e / γΐΛΐ 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 inside surface 45 (see FIG. 3B) of the third side 13 and an inside surface 42 (see FIG. 2B) of the first side 11. The obtuse angle 40 extends from the top end 15 of the utility cabinet 10 to the bottom end 16 of the utility cabinet 10. The second opposite end 37 of the fourth side 14 forms an acute angle 39 between an inside surface 45A of the fourth side 14 and an inside surface 42 of the first side 11, and the acute angle 39 extends from the top end 15 of the utility cabinet 10 to the bottom end 16 of the utility cabinet 10. The angled edges of the second opposite ends 35 and 37 of sides 13 and 14 rest on the angled edges of ends 31 and 33 of sides 11 and 14. 12. Sides 11, 12, 13 and 14 may have openings 19 to accommodate wires, pipes, tubes, and the like. Figure 2A is a perspective view from an outer surface 41 of the first side 11, separate from the service cabinet 10, and Figure 2B is a perspective view from an inner surface 42 of the first side 11. The hinge members 24, housings 27, and interiors 28 can be seen in more detail. The grooves or spaces 43 between the hinge members 24 accommodate the housings 27 of the hinge members 24 that engage with the first side 11 to complete the formation of the hinges 23. Figure 3A is a perspective view from an exterior surface 44 of the third side 13 separated from the service cabinet 10, and Figure 3B is a perspective view from an interior surface 45. The hinge members 24, housings 27, and interiors 28 can be seen in more detail. Figures 3A and 3B further show latches 46 that lock the third side 13 to the first side 11 to prevent the service cabinet 10 from bending. The grooves 47 between the hinge members 24 accommodate the hinge member housings 27 that engage with the third side 13 to complete the formation of the hinges 20, 21, 22, and 23. The housings 27 reinforce the hinges 20, 21, 22, and 23 and protect them from external forces. When the utility cabinet 10 is placed on the ground to protect an underground device, soil, rocks, and cement can fill the interiors 28 of the housings 27, preventing the utility cabinet 10 from moving or bending. The first side 11 and the second side 12 are identical, and the third side 13 and the fourth side 14 are identical, even with respect to the articulation and folding characteristics. Figure 4 is a top view of the inner surface of the second side 12. Figure 5 is a top view of the inner surface of the third side 13. Figure 6 is a top view of the outer surface of the first side 11. The utility cabinet 10 is formed by inserting the housings 27 at end 35 of the third side 13 between the housings 27 at end 31 of the second side 12 and by inserting the housings 27 at end 34 of the third side 13 between the housings 27 at end 30 of the first side 11. Bolts 26 are then inserted through holes 25 to form hinges 20, 21, 22, and 23. The fourth side 14 is added to sides 11 and 12 in the same manner to complete the assembly of the utility cabinet 10. Figure 7A is a top perspective view of the utility cabinet 10 positioned with its first side 11 in a horizontal plane, indicated by a double arrow 50. The utility cabinet 10 is in an unfolded configuration. Figure 7B shows the utility cabinet 10 in a semi-folded configuration. Figure 7C shows the utility cabinet 10 in a fully folded configuration. As the second side 13 is rotated away from the first side 11, the fourth side 14 is rotated toward the first side 11. The second side 12 moves inward toward the first side 11. In the folded configuration, the utility cabinet 10 is approximately 15% to 25% thick, compared to the unfolded configuration, preferably approximately 20%. Figure 8A shows an enlarged top view of end 33 of the second side 12 and end 35 of the third side 13 in an unfolded configuration. Figure 8B shows an enlarged top view of end 32 of the second side 12 and end 36 of the fourth side 14 in an unfolded position. The utility cabinet 10 cannot be folded in a direction opposite to that shown in Figures 9A, 9B, 10A, and 10C because end 35 of side 13 abuts end 33 of side 12, shown by arrow 51, at an angle to sides 12 and 13. End 35 of side 13 cannot move around end 33 of side 12. However, end 36 of side 14 can move around end 32 of side 12, as shown in Figures 9A, 9B, 10A, and 10C. 9A, 9B, 10A and 10C, because end 36 overlaps end 32, shown by arrow 52. Figures 9A and 9B show the same views as Figures 8A and 8B, but with the service cabinet 10 in a semi-folded configuration. Arrow 53 in Figure 9A shows how far end 35 of side 13 has moved away from end 33 of side 12. Arrow 54 in Figure 9B shows how far end 36 of side 14 has moved over and around the curved extension 38 of end 32 of side 12. Figures 10A and 10B show the same views as Figures 8A and 8B. 8A and 8B, but with the utility cabinet 10 in a fully folded configuration with the first side 11 attached to the second side 12. The folding of the utility cabinet 10 is reversible and the utility cabinet 10 can be restored to its unfolded configuration by pulling the first side 11 and the second side 12 apart. FIG. 11 shows a top perspective view of the utility cabinet 10 with a top cover 60 inserted at the top end 15. The top cover 60 may 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 cabinet 10 can be viewed and accessed by lifting the door 63. Figure 13 shows a bottom perspective view of the utility cabinet 10 with a bottom cover 64 reversibly attached to the bottom end 16 by methods known in the art. The use of a bottom cover 64 allows the utility cabinet 10 to be used as any type of utility cabinet for any type of item. en yiin / eznz / e / γΐΛΐ Figure 14 shows a perspective view of a hinged corner connecting two sides, with a locking bolt 70 inserted through the hinge members 24 to prevent rotation of the hinge sides and to prevent folding of the collapsible plastic / composite utility cabinet. There is an insertion hole 71 at the upper end 15 for inserting the locking bolt 70. Each hinge member 24 has an upper groove 72 and a lower groove 73 through which the locking bolt 70 passes. The locking bolt 70 can be retained in an opening 74 in the lower hinge member. Sides 11, 12, 13, and 14 of the utility cabinet 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 its temperature can range from 180 to over 121°C (250°F). The outer surface of the side is hardened, but the inner portion may 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 immediately start to warp, rendering it unusable. To prevent warping, the side can be placed on a cooling rack immediately after removal from the mold. The cooling rack in yiin / eznz / e / GALA holds the side in a fixed configuration until the internal plastic solidifies and the temperature has cooled below 82.22°C (180°F).The cooling rack prevents the side from warping, but the side must remain on the cooling rack for up to 60 minutes. This amount of time makes the manufacturing process impractical. Another problem arises when drilling a center hole 25 in the hinge member 24 for the insertion of a hinge pin 26. Since the hinge members are made of glass-reinforced thermoplastic, the time required to drill the center hole in the hinge member is up to 20 minutes. Furthermore, the drill bit wears down after drilling three or four holes. This amount of time and drill bit wear also makes the manufacturing process impractical. To overcome these manufacturing problems, the mold was designed to form the center hole in the hinge member during the side molding process. Figure 15 shows two mold parts 101 and 102 of a mold 100, where the two mold parts 101 and 102 form the hinge member. Part 101 has a solid center portion 103 that forms the center hole in the hinge member. Likewise, part 102 has a solid center portion 104 that forms the center hole in the hinge member. The combination of center holes, formed by parts 101 and 102 and extending through the plurality of spaced hinge members, forms the hinge. With the hinge member reduced in mass, the cooling time in the mold is reduced. At the end of the curing in the molds, the sides are removed from the molds with the central hole formed in the hinge member.The utility cabinet can be assembled with the hinge pins inserted into the center holes of the hinge members within approximately 10 minutes of removing the sides from the molds. Assembling the utility cabinet and inserting the hinge pins into the hinge members while the sides are still warm from the molding process remarkably prevents warping during cooling. Furthermore, the utility cabinets can be left to cool in the folded configuration for easier shipping or storage. The material used to form the sides can be any polymer or composite, preferably a glass fiber reinforced thermoplastic or a polymer-graphene thermoplastic composite. The thermoplastic is preferably polypropylene. Glass fiber reinforced polypropylene has improved dimensional stability, reduced warping, increased stiffness, and increased strength. The heat deflection temperature at 17.6506 bar (264 psi) increases to 300°F (150°C) for polypropylene reinforced with 40% glass fiber. The coefficient of thermal expansion of polypropylene is halved with 40% glass reinforcement. Glass fiber reinforced polypropylene has good impact resistance, very good mold filling capacity, excellent stiffness, good dimensional stability, and low creep under load at elevated temperatures (RTP Company, Winona, Minnesota). The foregoing description illustrates and describes the description. Furthermore, the description shows and describes only the preferred embodiments, but it should be understood that the preferred embodiments can be formed in various other combinations, modifications, and settings and are capable of changes or modifications within the scope of the concepts of the invention as expressed herein, in accordance with prior learning and / or relevant skill or knowledge of the art. The embodiments described herein are further intended to explain the best modes known to the applicant and to enable other persons skilled in the art to use the description in such or other embodiments and with the various modifications required by particular applications or uses thereof. Accordingly, the description is not intended to limit the invention to the form described herein.Furthermore, the appended claims are intended to be interpreted to include alternative embodiments. It is further understood that persons skilled in the art may make various changes to the details, materials, and arrangements of the parts described and illustrated above to explain the nature of this invention without departing from the principle and scope of the invention as set forth in the following claims. It is hereby stated that, as of this date, the best method known to the applicant for putting the aforementioned invention into practice is the one that is clear from the present description of the invention.

Claims

1. A method for forming a foldable plastic and / or composite cabinet, wherein the foldable plastic and / or composite cabinet comprises: a) a first side, a second side opposite the first side, a third side, and a fourth side opposite the third side, each side 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 hinge members, wherein each hinge member has a central hole, wherein each hinge is formed by the spaced hinge members, and wherein each hinge has a single hinge pin extending through the central holes of the spaced hinge members forming the hinge, characterized in that it comprises: a) providing molds for forming 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 suitable molding material and placing the material in molds to form the sides; c) removing the sides from the molds after curing the material in the molds;(yd) assemble the sides to form the utility cabinet while the sides are still hot from the molding process and insert hinge pins into the center holes of the hinge members spaced to form the hinges to prevent the sides from warping during the cooling of the utility cabinet.

2. The method according to claim 1, characterized in that it further comprises 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 forming the central hole.

3. The method according to claim 1, characterized in that assembling the sides and inserting the hinge pins is completed within approximately 10 minutes after removing the sides from the molds.

4. The method according to claim 1, characterized in that the material is a fiberglass reinforced composite.

5. The method according to claim 1, characterized in that the material is polypropylene.

6. The method according to claim 1, characterized in that the material is a composite of thermoplastic polymer and graphene.

7. The method according to claim 1, characterized in that the material is a polymer or a compound.

8. A method for forming a foldable plastic and / or composite cabinet, wherein the foldable plastic and / or composite cabinet comprises: a) a first side, a second side opposite the first side, a third side, and a fourth side opposite the third side, each side 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 hinge members, wherein each hinge member has a central hole, wherein each hinge is formed by the spaced hinge members, and wherein each hinge has a single hinge pin extending through the central holes of the spaced hinge members forming the hinge, characterized in that it comprises: a) providing a mold or molds for forming 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 suitable plastic or compound for molding and placing the plastic or compound in the mold or molds to form the sides;c) molding the center hole of the hinge member with two molding parts, wherein one molding part or both molding parts have a solid center portion forming the center hole; d) removing the sides from the molds after the plastic has cured in the molds; e) assembling the sides to form the utility cabinet while the sides are still hot from the molding process and inserting hinge pins into the center holes of the hinge members spaced to form the hinges to prevent the sides from warping during cooling of the utility cabinet.

9. The method according to claim 8, characterized in that assembling the sides and inserting the hinge pins is completed within approximately 10 minutes after removing the sides from the molds.

10. The method according to claim 8, characterized in that the compound is a glass fiber reinforced thermoplastic compound.

11. The method according to claim 10, characterized in that the thermoplastic is polypropylene.

12. The method according to claim 8, characterized in that the compound is a polymer-graphene compound and the polymer is a thermoplastic.

13. The method according to claim 8, characterized in that the plastic is a polymer. in yiin / eznz / e / γΐΛΐ 14. A method for forming a foldable plastic and / or composite cabinet, wherein the foldable plastic and / or composite cabinet comprises: a) a first side, a second side opposite the first side, a third side, and a fourth side opposite the third side, each side 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 hinge members, wherein each hinge member has a central hole, wherein each hinge is formed by the spaced hinge members, and wherein each hinge has a single hinge pin extending through the central holes of the spaced hinge members forming the hinge, in yiin / eznz / e / γΐΛΐ characterized in that it comprises: a) providing molds for forming 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 suitable plastic or compound for molding and placing the plastic or compound in molds to form the sides;c) molding the center hole of the hinge member with two molding parts, wherein one or both molding parts have a solid center portion forming the center hole; d) removing the sides from the molds after the plastic has cured in the molds; e) assembling the sides to form the utility cabinet while the sides are still hot from the molding process and inserting hinge pins into the center holes of the hinge members spaced to form the hinges to prevent the sides from warping during the cooling of the utility cabinet, wherein the assembly of the sides and the insertion of the hinge pins is completed within approximately 10 minutes after removing the sides from the molds.

15. The method according to claim 14, cnj iin / cznz / e / YiAi characterized in that the compound is a glass fiber reinforced thermoplastic compound.

16. The method according to claim 15, characterized in that the thermoplastic is polypropylene.

17. The method according to claim 14, characterized in that the compound is a polymer-graphene compound and the polymer is a thermoplastic.

18. The method according to claim 14, characterized in that the plastic is a polymer.

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