CN110934366A - Foam clothes - Google Patents

Abstract

The present invention relates to a three-dimensional foam garment molded from a vacuum molding or thermoforming machine that can mold two sheets of plastic simultaneously. The vacuum molding or thermoforming machine includes two female molds that are positioned one on top of the other and an opening mechanism for opening and closing the two molds. The vacuum molding or thermoforming machine receives two plastic sheets at a time and provides air between the two plastic sheets to force each plastic sheet into a mold to form a three-dimensional garment, wherein the edges of the garment are sealed.

Description

Foam clothes

Technical Field

The invention relates to a process for making clothes by using foam.

Background

Apparel, and Hallowmas apparel or outfits in particular, have become a vast industry. There are many different types of garments on the market. Some people are quite creative and may combine their home items to form a garment, including pirate suits with simple eye patches or ghost suits with sheet material.

In the past, halloween garments included pajamas, simple nylon made personalized apparel that people could simply wear their favorite princess garments.

Some patents relate to movable three-dimensional articles such as wings that are supported by a central housing and have a rod assembly that allows the wings to move relative to the central housing.

To a curved member that can be covered by foam or by fabric to become a three-dimensional garment for use on a cosmetic dance. There are also garments into which the foam elements are sewn.

Some garments even use high technology. Some garments include a small fan/air machine to blow up the garment to keep the garment inflated. Still further garments are illuminated with LED lighting devices which may be of simple design or all be positioned over the entire garment.

It is therefore desirable to create and design new and different types of halloween apparel.

Disclosure of Invention

The present invention relates to shaped garments, and in particular to halloween garments made from foam. The foam or polymer layer is vacuum molded, and more specifically, two plastic or polymer sheets are vacuum molded simultaneously to form a three-dimensional garment.

Common names for these types of machines include vacuum forming machines, thermoforming machines, sheet fed vacuum forming machines, foam packaging machines, and the like.

The molded articles formed with standard molding machines are simple sheets. To manufacture a three-dimensional article, two separate pieces must be formed each, sealed together (using adhesive or sewing), and then trimmed at the edges. Therefore, there is a need for a method that can form a three-dimensional garment in one step.

Three-dimensional foam garments are formed using a special vacuum molding machine modified to include two female molds. The vacuum molding machine further includes a mechanism for separating the two molds such that in the open position the two molds are at least 30 inches apart. Two heated plastic sheets are placed between the two molds and the vacuum molding machine is closed. Air is forced between the two sheets to force the two plastic sheets outward into each mold. Vacuum is then applied from the outside of the mold to remove trapped air between the plastic sheet and the mold and draw the material into or onto the mold, plus the force of the pressurized air from inside into between the plastic sheets to shape and match the detailed shape of the mold. The vacuum molding machine is turned on and the sealed three-dimensional garment is removed from the mold.

Vacuum forming is a form of thermoforming whereby a plastic sheet is heated to a forming temperature, stretched into or into a single-faced mold, and held against the mold by application of a vacuum between the mold surface and the plastic sheet. Vacuum forming processes can be used to manufacture most product packaging, speaker housings, and even automotive dashboards. Vacuum forming is generally, but not always, limited to forming plastic parts with shallow depths. The sheet may be formed into rigid cavities for use in unit doses of medicament and for use in bulk items listed as or becoming items for sale. The sheet may be formed into durable articles such as pavement markers and protective covers. Deeper parts can be formed if the sheet is stretched mechanically or pneumatically before the formable sheet is brought into contact with the mold surface and before the vacuum is applied.

Thin thermoforming is used primarily to make disposable cups, containers, lids, trays, blister-cases, clam-cases, and other products used in the food, pharmaceutical and general retail industries. Thick thermoforming involves the manufacture of various components such as vehicle doors and instrument panels, refrigerator liners, utility vehicle chassis, and plastic pallets.

Other thermoforming processes add the advantages of matched molds (using male and female molds). In the most common method of continuous bulk thermoforming of thin products, the plastic sheet is fed from a roll or extruder to a set of transfer chains comprising pins or spikes that penetrate into the sheet and is conveyed through an oven to be heated to the forming temperature. The heated sheet of plastic is then transferred to a forming station where mating molds (including a "male mold and a" female mold) and a pressure box are closed on the plastic sheet. Vacuum is then applied to remove trapped air and to draw material into or onto the mold with the pressurized air, thereby shaping the sheet to match the detailed shape of the mold. (in the case of taller, deeper stretch-formed parts, plug-assist is typically used in addition to the vacuum to form the desired material distribution and thickness in the final part.) after a short forming cycle, as the forming tool opens, a reverse air pressure, commonly referred to as an air jet, is actuated from the vacuum side of the mold, breaking the vacuum and assisting in removing the formed part from the mold.

Heavy-duty forming uses the same basic process as thin sheet forming, typically by overlaying a heated plastic sheet onto a mold. Many heavy duty forming applications use vacuum only in the forming process, but some use two halves of a mating forming tool and include air pressure to assist in forming the material. In world war ii, aircraft windshields and gun swivel seat windows have accelerated the development of heavy-duty forming techniques. Heavy parts are used as decorative surfaces on durable structures such as automotive, refrigerator, spa and shower enclosure housings, and electrical and electronic equipment. Unlike most thin thermoformed parts, heavy parts are typically hand machined after forming to trim the final shape or to perform additional drilling, cutting, polishing depending on the product. Heavy-duty products typically have "durable" end-use properties, while thin products are more often designed to be disposable or reusable, and are primarily used to package or contain food products or products.

It is an object of the present invention to provide a method of forming a three-dimensional high detail garment or portion thereof in one step using vacuum molding.

Another object is to provide a vacuum molding machine that includes two molds and opens at least 30 inches to form a three-dimensional garment or portion thereof.

Advantageously, this reduces the tooling costs of prior art methods of manufacturing three-dimensional garments. This allows for the three-dimensional garment to be manufactured in one step, thereby reducing cycle time by half, since the two halves can be formed and sealed together simultaneously without the need for a second step or the use of an adhesive material.

Claims (4)

1. A vacuum molding or thermoforming machine for simultaneously molding two plastic sheets into a garment; the vacuum molding or thermoforming machine comprises:

two female dies that are recessed, the dies being positioned one on top of the other;

an opening mechanism for opening and closing the two molds;

a location for receiving two plastic sheets;

means for providing air pressure between two plastic sheets, thereby forcing each plastic sheet into one of the molds to form a three-dimensional garment, wherein edges of the garment are sealed.

2. A vacuum moulding or thermoforming machine as claimed in claim 1, characterised in that the vacuum moulding or thermoforming machine comprises means for providing vacuum pressure from outside the mould, thereby drawing air through the mould and drawing the plastic sheet against the mould to produce the detail.

3. The vacuum molding or thermoforming machine as claimed in claim 1, wherein the two molds are at least 30 inches apart when the vacuum molding or thermoforming machine is in an open position.

4. A method of forming a three-dimensional garment, the method comprising:

placing two molds in a vacuum molding machine, the vacuum molding machine being operable between an open position and a closed position, placing two sheets of plastic in the vacuum molding machine;

forcing air between the two plastic sheets to force the plastic sheets into the mold;

drawing air from outside the mold, thereby creating a vacuum to draw the plastic sheet against the mold;

once molding is complete, the air outside the mold is optionally reversed, thereby pushing the plastic sheet away from the mold to release the plastic sheet from the mold and making demolding easier;

and removing the three-dimensional garment from the mold while the edges thereof are sealed.