EP2001653A1 - A thermoforming method and article produced by the method - Google Patents

A thermoforming method and article produced by the method

Info

Publication number
EP2001653A1
EP2001653A1 EP07727540A EP07727540A EP2001653A1 EP 2001653 A1 EP2001653 A1 EP 2001653A1 EP 07727540 A EP07727540 A EP 07727540A EP 07727540 A EP07727540 A EP 07727540A EP 2001653 A1 EP2001653 A1 EP 2001653A1
Authority
EP
European Patent Office
Prior art keywords
sheet
over
unit
mould
thermoforming
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.)
Withdrawn
Application number
EP07727540A
Other languages
German (de)
French (fr)
Inventor
M. Omer Akbas
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Arcelik AS
Original Assignee
Arcelik AS
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Arcelik AS filed Critical Arcelik AS
Publication of EP2001653A1 publication Critical patent/EP2001653A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • B29C51/12—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 of articles having inserts or reinforcements
    • 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using 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
    • 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
    • B29C51/04—Combined thermoforming and prestretching, e.g. biaxial stretching
    • B29C51/06—Combined thermoforming and prestretching, e.g. biaxial stretching using pressure difference for prestretching
    • 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
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
    • 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
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • 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
    • B29L2031/762—Household appliances
    • B29L2031/7622—Refrigerators

Definitions

  • the present invention relates to a unit produced by thermoforming of plastic sheets.
  • Plastic units for example, the body or the body or door inner walls of refrigerators or containers used for storing purposes are formed by the thermoforming process.
  • the plastic units are generally shaped like a quadrangle box with one wide facade open.
  • Quadrangle shaped sheets of plastic material for example polystyrene - HIPS are used in order to form this shape.
  • the plastic sheet is heated to a certain temperature by heat sources like an infrared heater and after the heated and softened plastic sheet is clamped from the sides, is inflated by blowing air to one facade.
  • the mould is raised towards the void under the sheet, the sheet is pulled to the mould surface by vacuuming the air between the mould and the sheet and the sheet that is draped over the mould surface cools and resumes its final shape.
  • Deformations occur on the edges, folding regions and particularly on the corners of the plastic units thus produced due to excessive thinning of the material thickness.
  • cracks or perforations are formed as time goes by which result in user complaints.
  • plastic sheets having greater material thickness are used but this results in the increase of material costs and energy consumption.
  • the thinned regions over the mould are mended by plastering plastic material later on.
  • a refrigerator cabin is produced by injecting an insulation material between the inner liner and the outer wall. After the inner liner is formed in the thermoforming mould, part of or the remainder of the sandwich construction is added on to the thermo-formed object in order to increase its stiffness prior to form ejection and subsequent transportation and use.
  • the aim of the present invention is the realization of a unit produced by thermoforming of plastic sheets with increased durability.
  • the unit of the present invention is produced by thermoforming process, the regions on the plastic sheet to be used for the production of the unit corresponding to the parts like corners, edges or folds that are foreseen to be over-thinned are reinforced by plastic material prior to thermoforming or the plastic sheet is directly produced by increasing the thickness of the regions that are probable to be over-thinned.
  • a patch is glued on the regions of the plastic sheet that are probable to be over-thinned before the ther- moforming process.
  • the patch is produced of a material suitable for thermoforming, the same or of a different plastic material than the sheet.
  • the patch is shaped like a sheet that will cover the thinning regions and is adhered on the plastic sheet by chemical adhesives or by pressure welding method.
  • the plastic sheet is produced with an increased material thickness at regions likely to be over-thinned.
  • Figure 1 - is the sectional view of a plastic sheet used to produce the plastic unit.
  • Figure 2 - is the sectional view of a plastic sheet used to produce the plastic unit in another embodiment of the present invention.
  • Figure 3 - is the schematic view of a plastic sheet and a thermoform mould wherein the plastic sheet is shaped.
  • Figure 4 - is the schematic view of a plastic sheet wherein thinning regions are determined and a unit produced of a plastic sheet.
  • the unit (1) used for various purposes is produced by thermoforming a sheet (L) of plastic material over a mould (K).
  • the unit (1) is produced of a sheet (L) that is reinforced at regions (B) corresponding to probable over-thinning parts like the corner, edge or fold by plastic material over the mould (K) prior to thermoforming process.
  • a plastic sheet (L) is used of which the thickness of probable over-thinning regions (B) are increased with respect to other regions.
  • the parts that can have the problem of over-thinning and to which regions (B) they correspond on the yet unformed sheet (L) are determined by the producer by various methods
  • units (1) shaped like a quadrilateral prism with an open fecade there are more than one corner wherein the sides join and it is foreseen that over-thinning will occur mainly at the corners or in the vicinity thereof while the sheet (L) is shaped over the mould (K).
  • the regions (B) of the sheet (L) corresponding to the corners and their vicinity of the unit (1) are thickened by reinforcing with plastic material prior to ther- moforming and a durable structure is attained on the corner zones of the unit (1) ( Figure 4).
  • the unit (1) is made of a plastic sheet (L) that comprises one or more patches (2), shaped like a plate for covering the thinning region (B), adhered to the probable over- thinning regions (B) over the mould (K) prior to thermoforming ( Figure 1).
  • the patch (2) is produced of a material suitable for thermoforming, from the same or different plastic as that of the sheet (L). Since thermoforming is applied together on the patch (2) and the sheet (L) on which it is adhered, the seam will practically disappear after thermoforming, presenting an advantage of esthetic appearance.
  • the patch (2) is adhered on the sheet (L) on the probable thinning regions (B) over the mould (K) by chemical adhesives or by pressure welding methods.
  • the probable over-thinning regions (B) of the sheet (L) are reinforced by increasing the material thickness without adhering a second material on the sheet (L).
  • a sheet (L) comprising one or more protrusions (3) on one or both sides is used, having a shape suitable for the probable thinning regions (B), and formed by increasing the material thickness in the probable over-thinning regions (B) ( Figure 2).
  • the unit (1) produced of a sheet (L) with increased material thickness or with adhered patch (2) prior to thermoforming is used in the production of the inner walls of the body and/or the door of refrigerators or containers for storage.
  • the unit (1) production method is comprised of the following steps:
  • the heated and softened sheet (L) is fixed from the sides.
  • the sheet (L) is inflated by blowing air from one surf ⁇ ce.
  • the mould (K) is raised towards the void under the inflated sheet (L).
  • the sheets (L) will cool homogeneously in less time and the latent stress that can cause cracks on the inner wall later on is reduced.
  • the total production turnover duration and costs are reduced, increasing the production volume.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Refrigerator Housings (AREA)

Abstract

The present invention relates to a plastic unit (1) used in the production of refrigerator doors and/or bodies or plastic containers, made of a sheet (L) of plastic material by thermoforming over a mould (K) and increasing the durability by determining the regions (B) wherein probable over-thinning of the material thickness can occur after being shaped in the mould (K).

Description

Description
A THERMOFORMING METHOD AND ARTICLE PRODUCED BY THE METHOD
[0001] The present invention relates to a unit produced by thermoforming of plastic sheets.
[0002] Plastic units, for example, the body or the body or door inner walls of refrigerators or containers used for storing purposes are formed by the thermoforming process. The plastic units are generally shaped like a quadrangle box with one wide facade open. Quadrangle shaped sheets of plastic material for example polystyrene - HIPS are used in order to form this shape. For the thermoforming process, the plastic sheet is heated to a certain temperature by heat sources like an infrared heater and after the heated and softened plastic sheet is clamped from the sides, is inflated by blowing air to one facade. Then the mould is raised towards the void under the sheet, the sheet is pulled to the mould surface by vacuuming the air between the mould and the sheet and the sheet that is draped over the mould surface cools and resumes its final shape. Deformations occur on the edges, folding regions and particularly on the corners of the plastic units thus produced due to excessive thinning of the material thickness. During the usage of the plastic unit, cracks or perforations are formed as time goes by which result in user complaints. In order to prevent over-thinning, generally plastic sheets having greater material thickness are used but this results in the increase of material costs and energy consumption. In some of the applications, the thinned regions over the mould are mended by plastering plastic material later on.
[0003] In the European patent document no. EP0611644, a refrigerator cabin is produced by injecting an insulation material between the inner liner and the outer wall. After the inner liner is formed in the thermoforming mould, part of or the remainder of the sandwich construction is added on to the thermo-formed object in order to increase its stiffness prior to form ejection and subsequent transportation and use.
[0004] The aim of the present invention is the realization of a unit produced by thermoforming of plastic sheets with increased durability.
[0005] The unit realized in order to attain the aim of the present invention is explicated in the attached claims.
[0006] The unit of the present invention is produced by thermoforming process, the regions on the plastic sheet to be used for the production of the unit corresponding to the parts like corners, edges or folds that are foreseen to be over-thinned are reinforced by plastic material prior to thermoforming or the plastic sheet is directly produced by increasing the thickness of the regions that are probable to be over-thinned. [0007] In the preferred errbodiment of the present invention, a patch is glued on the regions of the plastic sheet that are probable to be over-thinned before the ther- moforming process. The patch is produced of a material suitable for thermoforming, the same or of a different plastic material than the sheet. The patch is shaped like a sheet that will cover the thinning regions and is adhered on the plastic sheet by chemical adhesives or by pressure welding method.
[0008] In another embodiment of the present invention, the plastic sheet is produced with an increased material thickness at regions likely to be over-thinned.
[0009] In the production of the unit of the present invention, use of plastic sheets with extra material thickness is not required and material savings can be made, for example the deformations that can occur due to thinning at the inner wall corners of refrigerators are prevented.
[0010] The unit realized in order to attain the aim of the present invention is illustrated in the attached figures, where:
[0011] Figure 1 - is the sectional view of a plastic sheet used to produce the plastic unit.
[0012] Figure 2 - is the sectional view of a plastic sheet used to produce the plastic unit in another embodiment of the present invention.
[0013] Figure 3 - is the schematic view of a plastic sheet and a thermoform mould wherein the plastic sheet is shaped.
[0014] Figure 4 - is the schematic view of a plastic sheet wherein thinning regions are determined and a unit produced of a plastic sheet.
[0015] The elements illustrated in the figures are numbered as follows:
[0016] l. Unit
[0017] 2. Patch
[0018] 3. Protrusion
[0019] The unit (1) used for various purposes is produced by thermoforming a sheet (L) of plastic material over a mould (K).
[0020] The unit (1) is produced of a sheet (L) that is reinforced at regions (B) corresponding to probable over-thinning parts like the corner, edge or fold by plastic material over the mould (K) prior to thermoforming process.
[0021] In the production of the unit (1), a plastic sheet (L) is used of which the thickness of probable over-thinning regions (B) are increased with respect to other regions.
[0022] In the unit (1), the parts that can have the problem of over-thinning and to which regions (B) they correspond on the yet unformed sheet (L) are determined by the producer by various methods [0023] In units (1) shaped like a quadrilateral prism with an open fecade, there are more than one corner wherein the sides join and it is foreseen that over-thinning will occur mainly at the corners or in the vicinity thereof while the sheet (L) is shaped over the mould (K). The regions (B) of the sheet (L) corresponding to the corners and their vicinity of the unit (1) are thickened by reinforcing with plastic material prior to ther- moforming and a durable structure is attained on the corner zones of the unit (1) (Figure 4).
[0024] In the preferred embodiment of the present invention, the unit (1) is made of a plastic sheet (L) that comprises one or more patches (2), shaped like a plate for covering the thinning region (B), adhered to the probable over- thinning regions (B) over the mould (K) prior to thermoforming (Figure 1).
[0025] The patch (2) is produced of a material suitable for thermoforming, from the same or different plastic as that of the sheet (L). Since thermoforming is applied together on the patch (2) and the sheet (L) on which it is adhered, the seam will practically disappear after thermoforming, presenting an advantage of esthetic appearance.
[0026] The patch (2) is adhered on the sheet (L) on the probable thinning regions (B) over the mould (K) by chemical adhesives or by pressure welding methods.
[0027] In another embodiment of the present invention, the probable over-thinning regions (B) of the sheet (L) are reinforced by increasing the material thickness without adhering a second material on the sheet (L).
[0028] In this embodiment, in the production of the unit (1), a sheet (L) comprising one or more protrusions (3) on one or both sides is used, having a shape suitable for the probable thinning regions (B), and formed by increasing the material thickness in the probable over-thinning regions (B) (Figure 2).
[0029] The unit (1) produced of a sheet (L) with increased material thickness or with adhered patch (2) prior to thermoforming is used in the production of the inner walls of the body and/or the door of refrigerators or containers for storage.
[0030] The unit (1) production method is comprised of the following steps:
- The probable over-thinning regions (B) on the plastic sheet (L) are determined.
- Patch (2) is glued on the probable over-thinning regions (B) on the sheet (L) by injecting chemical substances or by plastic welding methods prior to thermoforming process.
- The sheet (L) is heated with the patch (2) glued on.
- The heated and softened sheet (L) is fixed from the sides. - The sheet (L) is inflated by blowing air from one surføce.
- The mould (K) is raised towards the void under the inflated sheet (L).
- The air left between the sheet (L) and the mould (K) is vacuumed and the sheet (L) is brought to the level of the mould (K).
- The sheet (L) is cooled and is taken out of the mould (K).
[0031] In the unit (1) of the present invention, deformation as a result of over- thinning is prevented and savings in material is incurred by determining which parts of the unformed sheet (L) correspond to the partially expected over-thinning regions (B), and by only increasing the material thickness of certain regions (B) instead of increasing the material thickness of the whole sheet (L) or by covering with patches (2).
[0032] By means of increasing the material thickness of the sheet (L) in regions (B) like the corners of the unit (1) wherein over- thinning problem can arise or by applying patches (2), preventive measure is taken instead of mending the thinned parts and over- thinning probability is averted. Furthermore, the entire sheet (L) material does not have be selected with a material thickness greater than required and sheets (L) with thinner material thickness than conventional implementations can be selected resulting in material savings. The thin sheets (L) can be heated to the desired temperature in the first heating phase of thermoforming process in a shorter period of time with less thermal energy. In the following inflating by pressurized air process after heating, the thin sheets (L) will inflate with less pressure in a shorter period of time. In the last phase of the thermoforming process, that is vacuuming and draping over the mould (K) and cooling, the sheets (L) will cool homogeneously in less time and the latent stress that can cause cracks on the inner wall later on is reduced. The total production turnover duration and costs are reduced, increasing the production volume.

Claims

Claims
[0001] A unit (1) formed by thermoforming a sheet (L) of plastic material over a mould
(K), characterized by a sheet (L) that is reinforced at the parts corresponding to the probable over-thinning regions (B) like the corner, edge or fold by plastic material prior to thermoforming.
[0002] A unit (1) as in Claim 1, characterized by a sheet (L) of which the material thickness of probable over-thinning regions (B) are increased with respect to other parts thereof.
[0003] A unit (1) as in Claim 1 or 2, characterized by a sheet (L) comprising one or more patches (2) shaped like a plate, covering the thinning region (B), adhered to the probable over-thinning regions (B) over the mould (K) prior to the thermoforming process.
[0004] A unit (1) as in Claim 3, characterized by a sheet (L) comprising a patch (2) produced of a material suitable for thermoforming, the same or of a different plastic than the sheet (L).
[0005] A unit (1) as in Claim 3 or 4, characterized by a sheet (L) comprising a patch
(2) adhered by chemical adhesives on the probable over-thinning regions (B) over the mould (K) prior to thermoforming .
[0006] A unit (1) as in Claim 3 or 4, characterized by a sheet (L) comprising a patch
(2) adhered by pressure welding on the probable over-thinning regions (B) over the mould (K) prior to thermoforming.
[0007] A unit (1) as in Claim 1 or 2, characterized by a sheet (L) comprising one or more protrusions (3) formed by increasing the material thickness of the probable over-thinning regions (B) and suitably shaped for the probable over-thinning regions (B).
[0008] A refrigerator characterized by a unit (1) as in any one of the above claims that can be used as the inner wall of the body and/or the door.
[0009] A production method for a unit (1) as in Claim 3, comprising the steps of : determining the probable over-thinning regions(B) on the plastic sheet (L), gluing the patch (2) on the probable over-thinning regions (B) on the sheet (L) by injecting chemical substances or by plastic welding methods prior to thermoforming process, heating of the sheet (L) with the patch (2) glued on, fixing of the heated and softened sheet (1) from the sides, inflating the sheet (L) by blowing air from one surface, raising the mould (k) towarcb the void under the inflated sheet (L), vacuuming the air left between the sheet (L) and the mould (K) and bringing the sheet (L) to the level of the mould (K), cooling the sheet (1) and taking out of the mould (K).
EP07727540A 2006-03-31 2007-03-30 A thermoforming method and article produced by the method Withdrawn EP2001653A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TR200601557 2006-03-31
PCT/EP2007/053068 WO2007113227A1 (en) 2006-03-31 2007-03-30 A thermoforming method and article produced by the method

Publications (1)

Publication Number Publication Date
EP2001653A1 true EP2001653A1 (en) 2008-12-17

Family

ID=38229248

Family Applications (1)

Application Number Title Priority Date Filing Date
EP07727540A Withdrawn EP2001653A1 (en) 2006-03-31 2007-03-30 A thermoforming method and article produced by the method

Country Status (3)

Country Link
EP (1) EP2001653A1 (en)
CN (1) CN101415534A (en)
WO (1) WO2007113227A1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011129709A2 (en) * 2010-04-12 2011-10-20 Tarvis Technology Limited Cup, cup forming apparatus and related methods
CN112923648A (en) * 2019-12-06 2021-06-08 青岛海尔电冰箱有限公司 Inner container plate, inner container and refrigerator

Family Cites Families (5)

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Publication number Priority date Publication date Assignee Title
DE1779463B1 (en) * 1968-08-14 1972-03-09 Thiel Alfons W PROCESS FOR PRODUCING SHAPED PARTS FROM A STRIP OF THERMOPLASTIC PLASTIC AND DEVICE FOR CARRYING OUT THE PROCESS
DE2643320A1 (en) * 1976-09-25 1978-03-30 Zorn E E Gmbh Co Kg CONTAINER, IN PARTICULAR EXTERIOR PANELING FOR A HARD COOLER, AND METHOD FOR MANUFACTURING A CONTAINER
JPS581518A (en) * 1981-06-29 1983-01-06 Nec Home Electronics Ltd Preparation of vacuum molded parts
DE3219426C2 (en) * 1982-05-03 1984-03-22 Liebherr-Hausgeräte GmbH, 7955 Ochsenhausen Method for deep-drawing an inner container having chambers with widely differing volumes for a refrigerator and freezer or the like
JPH05305654A (en) * 1992-04-28 1993-11-19 Asahi Chem Ind Co Ltd Composite panel for thermoforming

Non-Patent Citations (1)

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Title
See references of WO2007113227A1 *

Also Published As

Publication number Publication date
WO2007113227A1 (en) 2007-10-11
CN101415534A (en) 2009-04-22

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