CA2287718A1 - Method for fabricating thermoformed plastic laminate articles - Google Patents
Method for fabricating thermoformed plastic laminate articles Download PDFInfo
- Publication number
- CA2287718A1 CA2287718A1 CA002287718A CA2287718A CA2287718A1 CA 2287718 A1 CA2287718 A1 CA 2287718A1 CA 002287718 A CA002287718 A CA 002287718A CA 2287718 A CA2287718 A CA 2287718A CA 2287718 A1 CA2287718 A1 CA 2287718A1
- Authority
- CA
- Canada
- Prior art keywords
- mould
- female
- process according
- article
- shell
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
- B29C63/22—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using layers or sheathings having a shape adapted to the shape of the article
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/10—Forming by pressure difference, e.g. vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2009/00—Layered products
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2022/00—Hollow articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/40—Test specimens ; Models, e.g. model cars ; Probes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/02—2 layers
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
Abstract
A process for making laminate articles, which includes fabricating a prototype article having an article interface surface, making a female mould from the prototype article, and forming a male mould from the female mould. An inner shell is then made from the female mould and an outer shell from the male mould.
The inner and outer shells are bonded together to form a laminate article.
The inner and outer shells are bonded together to form a laminate article.
Description
N~THOD FOR FABRICATING THERMOFORMED
PLASTIC LAMINATE ARTICLES
FIELD
The present invention relates to a process and apparatus for fabricating laminate articles having thermoplastic inner and outer shells.
BACFCGROUND
The fabrication of mufti-layered plastic articles in which the layers are bonded together produces a stiff article of a greater thickness than can be achieved with a single sheet.
However, any deficiency in the bond between the layers or shells results in a loss of strength in the laminate article. Thus, it is important to have shells which mate perfectly at their interface so that the bonding can be across the entire interface. In fabricating male and female moulds extreme accuracy is, therefore, required to match the mould surfaces. For parts having complex surfaces such accuracy is difficult to achieve. Elaborate jigs and measurement techniques are required when the moulds are to be fabricated manually. If computer controlled machines are used then the cost of these machines represents a significant expense.
Accordingly, it is an object of the invention to provide an improved method of fabricating thermoformed plastic articles.
It is a further object of the invention to provide a method of producing male and female moulds with interface surfaces formed with a high degree of accuracy.
PLASTIC LAMINATE ARTICLES
FIELD
The present invention relates to a process and apparatus for fabricating laminate articles having thermoplastic inner and outer shells.
BACFCGROUND
The fabrication of mufti-layered plastic articles in which the layers are bonded together produces a stiff article of a greater thickness than can be achieved with a single sheet.
However, any deficiency in the bond between the layers or shells results in a loss of strength in the laminate article. Thus, it is important to have shells which mate perfectly at their interface so that the bonding can be across the entire interface. In fabricating male and female moulds extreme accuracy is, therefore, required to match the mould surfaces. For parts having complex surfaces such accuracy is difficult to achieve. Elaborate jigs and measurement techniques are required when the moulds are to be fabricated manually. If computer controlled machines are used then the cost of these machines represents a significant expense.
Accordingly, it is an object of the invention to provide an improved method of fabricating thermoformed plastic articles.
It is a further object of the invention to provide a method of producing male and female moulds with interface surfaces formed with a high degree of accuracy.
SUMMARY OF THE INVENTION
According to the invention there is provided a process for making laminate articles, which includes fabricating a prototype article having an article interface surface, forming a female mould from the prototype article, and forming a male mould from the female mould. An inner shell is made from the female mould while an outer shell is made from the male mould. The inner shell is bonded to the outer shell to form a laminate article.
The female and male moulds may each be made of materials compatible with vacuum forming. The inner and outer shells are preferably made of coextruded thermoplastic material and are formed by thermoforming.
The co-extruded thermoplastic sheet may have a substrate layer of recycled material and a cap layer of protective material.
Features such as reinforcing, mounting brackets, and edge details may be affixed to a visible surface of the outer mould and a visible surface of the inner mould.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages will be apparent from the following detailed description, given by way of example, of a preferred embodiment taken in conjunction with the accompanying drawings, wherein:
According to the invention there is provided a process for making laminate articles, which includes fabricating a prototype article having an article interface surface, forming a female mould from the prototype article, and forming a male mould from the female mould. An inner shell is made from the female mould while an outer shell is made from the male mould. The inner shell is bonded to the outer shell to form a laminate article.
The female and male moulds may each be made of materials compatible with vacuum forming. The inner and outer shells are preferably made of coextruded thermoplastic material and are formed by thermoforming.
The co-extruded thermoplastic sheet may have a substrate layer of recycled material and a cap layer of protective material.
Features such as reinforcing, mounting brackets, and edge details may be affixed to a visible surface of the outer mould and a visible surface of the inner mould.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages will be apparent from the following detailed description, given by way of example, of a preferred embodiment taken in conjunction with the accompanying drawings, wherein:
Fig. 1 shows the various steps in fabricating a laminate article in accordance with a preferred embodiment of the invention;
and Fig. 2 is a sectional view of a laminate article formed in accordance with a preferred embodiment of the invention.
DETAILED DESCRIPTION WITH REFERENCE TO THE DRAWINGS
Referring to Fig. 1 a male prototype of an article 10 is first fabricated by conventional means such as milling, sawing, gluing, etc. Using the prototype, a split female mould 12 is made having an interface surface 14 that corresponds with the interface surface of the prototype 10. From the female mould 12 one again makes a male mould 16 having an interface surface 18. Having the female mould 12 split makes it easier to remove it from the male mould 16 Changes in design such as the addition of features 21A
and 23A to the female and male moulds 12 and 16, respectively, are added. Additional support, mounting or edge details 28 may then be added to the male mould.
Using the split female mould 12 one vacuum forms an inner shell 20 having an interface surface 22. Using the male mould 16 one vacuum forms an outer shell 24 having an interface surface 26.
Both sheets are each of coextruded or two-layer thermoplastic sheet having a substrate layer of recycled material and a cap layer of protective material. At this point the interface surfaces 22 of inner shell 20 and 26 of outer shell 24 match perfectly because that of outer shell 24 comes from the interface surface 18 of mould 16 which, in turn, is made from interface surface 14 of female mould 12 while that of inner shell 20 is also made from interface surface 14 of female mould 12. Once fabricated the shells 20 and 24 are trimmed on a 5-axis CNC router using customized holding fixtures and trimming programs. The edge geometry of the inner shell is generally designed to be different from that of the outer shell, consequently, the two shells are trimmed separately.
The final step of the process is to apply a bonding agent between the interface surfaces 22 and 26 prior to inserting the inner shell 20 into outer shell 24 and then using inner and outer frames combined with a pneumatic clamping system. An articulating fixture evenly distributes clamping force to allow simultaneous pressure over the entire bonding surface. The trimmed shells are bonded together using an adhesive having high bond strength and full recyclability. This adhesive is chemically similar to the shell materials and, therefore, does not introduce non-recyclable contaminants. At the end of its useful life, the two-shell laminated part can be ground up and extruded into new sheet. All components of the laminated part are recyclable without the need for a costly adhesive removal process. Figure 2 shows the completed laminated product 32 in cross-section, with inner shell 20 bonded to outer shell 24. Because of the fact that the interface surface of the male mold is taken directly from the interface surface of the female mold, the contacting surfaces of the inner and outer shells 20 and 24 match perfectly and fit together exactly at the bonding surfaces. Thus, a two shell laminated part is formed in which there is uniform bonding over the entire contact surface. Moreover, since the shell surfaces visible in the final part do not physically contact their respective molds, they, therefore, retain an optimal surface finish.
and Fig. 2 is a sectional view of a laminate article formed in accordance with a preferred embodiment of the invention.
DETAILED DESCRIPTION WITH REFERENCE TO THE DRAWINGS
Referring to Fig. 1 a male prototype of an article 10 is first fabricated by conventional means such as milling, sawing, gluing, etc. Using the prototype, a split female mould 12 is made having an interface surface 14 that corresponds with the interface surface of the prototype 10. From the female mould 12 one again makes a male mould 16 having an interface surface 18. Having the female mould 12 split makes it easier to remove it from the male mould 16 Changes in design such as the addition of features 21A
and 23A to the female and male moulds 12 and 16, respectively, are added. Additional support, mounting or edge details 28 may then be added to the male mould.
Using the split female mould 12 one vacuum forms an inner shell 20 having an interface surface 22. Using the male mould 16 one vacuum forms an outer shell 24 having an interface surface 26.
Both sheets are each of coextruded or two-layer thermoplastic sheet having a substrate layer of recycled material and a cap layer of protective material. At this point the interface surfaces 22 of inner shell 20 and 26 of outer shell 24 match perfectly because that of outer shell 24 comes from the interface surface 18 of mould 16 which, in turn, is made from interface surface 14 of female mould 12 while that of inner shell 20 is also made from interface surface 14 of female mould 12. Once fabricated the shells 20 and 24 are trimmed on a 5-axis CNC router using customized holding fixtures and trimming programs. The edge geometry of the inner shell is generally designed to be different from that of the outer shell, consequently, the two shells are trimmed separately.
The final step of the process is to apply a bonding agent between the interface surfaces 22 and 26 prior to inserting the inner shell 20 into outer shell 24 and then using inner and outer frames combined with a pneumatic clamping system. An articulating fixture evenly distributes clamping force to allow simultaneous pressure over the entire bonding surface. The trimmed shells are bonded together using an adhesive having high bond strength and full recyclability. This adhesive is chemically similar to the shell materials and, therefore, does not introduce non-recyclable contaminants. At the end of its useful life, the two-shell laminated part can be ground up and extruded into new sheet. All components of the laminated part are recyclable without the need for a costly adhesive removal process. Figure 2 shows the completed laminated product 32 in cross-section, with inner shell 20 bonded to outer shell 24. Because of the fact that the interface surface of the male mold is taken directly from the interface surface of the female mold, the contacting surfaces of the inner and outer shells 20 and 24 match perfectly and fit together exactly at the bonding surfaces. Thus, a two shell laminated part is formed in which there is uniform bonding over the entire contact surface. Moreover, since the shell surfaces visible in the final part do not physically contact their respective molds, they, therefore, retain an optimal surface finish.
5 While a simple geometric shape has been used for simplicity and convenience, obviously much more complex shapes could be involved.
Accordingly, while this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments as fall within the true scope of the invention.
Accordingly, while this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments as fall within the true scope of the invention.
Claims (7)
1. A process for making laminate articles, comprising:
(a) fabricating a prototype article having an article interface surface;
(b) making a female mould from said prototype;
(c) making a male mould from said female mould;
(d) forming an inner shell from said female mould;
(e) forming an outer shell from said male mould; and (f) bonding said inner shell to said outer shell to form a laminate article.
(a) fabricating a prototype article having an article interface surface;
(b) making a female mould from said prototype;
(c) making a male mould from said female mould;
(d) forming an inner shell from said female mould;
(e) forming an outer shell from said male mould; and (f) bonding said inner shell to said outer shell to form a laminate article.
2. A process according to claim 1, wherein said female and male moulds are each made of materials compatible with vacuum forming.
3. A process according to claim 1, including making said inner and outer shells of co-extruded thermoplastic sheet
4. A process according to claim 3, wherein said co-extruded thermoplastic sheet has a substrate layer of recycled material and a cap layer of protective material.
5. A process according to claim 1, including bonding an outer surface of said inner mould with an inner surface of said outer mould.
6. A process according to claim 1, including affixing features to one of an inner surface of said outer mould and an outer surface of said inner mould.
7. A process according to claim 5, wherein said bonding step employs an adhesive that is free of non-recyclable contaminants and material of said inner and outer shells is recyclable.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002287718A CA2287718A1 (en) | 1999-10-28 | 1999-10-28 | Method for fabricating thermoformed plastic laminate articles |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002287718A CA2287718A1 (en) | 1999-10-28 | 1999-10-28 | Method for fabricating thermoformed plastic laminate articles |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2287718A1 true CA2287718A1 (en) | 2001-04-28 |
Family
ID=4164504
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002287718A Abandoned CA2287718A1 (en) | 1999-10-28 | 1999-10-28 | Method for fabricating thermoformed plastic laminate articles |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2287718A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2010039713A1 (en) * | 2008-10-02 | 2010-04-08 | Dow Global Technologies Inc. | Gloss resins and method for making same |
-
1999
- 1999-10-28 CA CA002287718A patent/CA2287718A1/en not_active Abandoned
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2010039713A1 (en) * | 2008-10-02 | 2010-04-08 | Dow Global Technologies Inc. | Gloss resins and method for making same |
| US8603639B2 (en) | 2008-10-02 | 2013-12-10 | Dow Global Technologies Llc | Gloss resins and method for making same |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Dead |