US20180319073A1 - Method of vacuum forming an object using a flexible mold and an apparatus for vacuum forming an object - Google Patents
Method of vacuum forming an object using a flexible mold and an apparatus for vacuum forming an object Download PDFInfo
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- US20180319073A1 US20180319073A1 US16/039,882 US201816039882A US2018319073A1 US 20180319073 A1 US20180319073 A1 US 20180319073A1 US 201816039882 A US201816039882 A US 201816039882A US 2018319073 A1 US2018319073 A1 US 2018319073A1
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- mold
- base
- plastic sheet
- undercut
- rigid core
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Classifications
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- 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
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/30—Moulds
-
- 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
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/30—Moulds
- B29C51/34—Moulds for undercut articles
-
- 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
- B29C33/3842—Manufacturing moulds, e.g. shaping the mould surface by machining
- B29C33/3857—Manufacturing moulds, e.g. shaping the mould surface by machining by making impressions of one or more parts of models, e.g. shaped articles and including possible subsequent assembly of the parts
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- 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
- B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
- B29C33/48—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling
- B29C33/485—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling cores or mandrels
-
- 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
- B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
- B29C33/48—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling
- B29C33/50—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling elastic or flexible
-
- 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
-
- 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
- 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
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/30—Moulds
- B29C51/36—Moulds specially adapted for vacuum forming, Manufacture thereof
-
- 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
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/42—Heating or cooling
- B29C51/421—Heating or cooling of preforms, specially adapted for thermoforming
- B29C51/425—Heating or cooling of preforms, specially adapted for thermoforming using movable heating devices
-
- 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
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/44—Removing or ejecting moulded articles
-
- 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
- B29C33/40—Plastics, e.g. foam or rubber
- B29C33/405—Elastomers, e.g. rubber
-
- 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
Definitions
- the present teachings generally include a method of vacuum forming an object and an apparatus for vacuum forming an object.
- Vacuum forming is a process by which a plastic sheet is heated and then formed to the shape of a die by applying a vacuum to draw the sheet against the surface of the object. The die must then be withdrawn.
- Objects suitable for vacuum forming on a unitary rigid die have heretofore been limited to those that do not have undercuts, as an undercut prevents withdrawal of the die from the formed sheet without damage to the formed sheet.
- a complex, costly die with sliding die portions would be required to allow removal of the sheet.
- a method of vacuum forming an object includes heating a plastic sheet. After heating the plastic sheet, a vacuum is applied to conform pull the plastic sheet to a contoured shape of an outer surface of a flexible mold so that the plastic sheet has a formed shape that includes an undercut. Typically, such an undercut would cause a die lock condition. Vacuum forming of an object to achieve such a formed shape was therefore not an option.
- a rigid core is withdrawn from a cavity in the flexible mold.
- the flexible mold is then withdrawn from the plastic sheet by applying force to the flexible mold in a single direction, thereby causing flexing of the flexible mold past the undercut. Because the mold is flexible, the plastic sheet is formed to replicate the object, including the undercut.
- objects with undercuts that previously required more costly processes, such as a complex die assembly with slides, or injection molding, can instead be vacuum formed.
- An apparatus for forming an object from a plastic sheet includes a mold having an inner surface defining a cavity and having an outer surface that has a contoured shape.
- a rigid core is configured to fit within the cavity.
- a vacuum source is positioned to vacuum form the plastic sheet to the outer surface of the mold to form the object having a formed shape, including an undercut, that conforms to the contoured shape of the mold.
- the formed shape includes an undercut.
- the mold is flexible, allowing the mold to be withdrawn from the plastic sheet past the undercut by applying force in a single direction after the rigid core is withdrawn from the cavity.
- FIG. 1 is a schematic illustration in perspective view of an article to be replicated that is a scale model of a pickup truck to be replicated.
- FIG. 2 is a schematic illustration in perspective view of a vacuum-formed plastic sheet replicating the scale model of FIG. 1 .
- FIG. 3 is a schematic illustration in another perspective view of the vacuum-formed plastic sheet of FIG. 2 .
- FIG. 4 is a schematic illustration in side view of a flexible mold supported on a rigid core (shown in hidden lines) and on a base.
- FIG. 5 is a schematic illustration in perspective view of the rigid core supported on the base of FIG. 4 .
- FIG. 6 is a schematic illustration in perspective view of a container containing the article of FIG. 1 in mold material.
- FIG. 7 is a schematic illustration in plan view of the container of FIG. 6 with the base suspending the rigid core above a female mold formed in FIG. 6 .
- FIG. 8 is a schematic cross-sectional illustration taken at lines 8 - 8 in FIG. 7 of the rigid core suspended above the female mold formed in FIG. 6 and with mold material poured in a gap to create the flexible mold of FIG. 4 .
- FIG. 9 is a schematic illustration in perspective view of the plastic sheet clamped to an oven tray and an oven into which the tray is inserted and removed.
- FIG. 10 is a schematic illustration in perspective view of the plastic sheet positioned above the mold assembly and base of FIG. 4 and with a vacuum source connected to the base.
- FIG. 11 is a schematic illustration in cross-sectional view of the plastic sheet vacuum formed to the flexible mold of FIG. 4 and showing a cooling fan.
- FIG. 12 is a schematic illustration in cross-sectional view of the rigid core withdrawn from the flexible mold.
- FIG. 13 is a schematic illustration in cross-sectional view of the flexible mold flexing to move past undercuts in the vacuum formed sheet.
- FIG. 14 is a flow diagram of a method of vacuum forming an object.
- FIG. 1 shows an article 10 to be replicated by a method 100 described herein and represented in the flow diagram of FIG. 14 .
- the article 10 is a scale model of a pickup truck. It should be appreciated that the article 10 is only one example embodiment of an article that can be replicated by the method 100 , and the method 100 can be applied to replicate other articles. More specifically, the method 100 is particularly useful for replicating an article that has an undercut that creates a die lock condition that makes a conventional vacuum forming process with a unitary rigid die unusable.
- an “undercut” is an angle of a portion of the outer surface of the formed object relative to a base on which a mold for the object is mounted that makes it impossible to remove the mold from the formed object by applying only a force in a single direction to the mold.
- the article 10 of FIG. 1 has wheel wells 12 over tire and wheel assemblies 13 , a front bumper 14 and a rear bumper 16 , all of which result in undercuts in a vacuum formed plastic sheet 18 formed over a flexible mold 20 of the article 10 , as shown in FIG. 11 .
- the object 10 A formed from the plastic sheet 18 has undercuts 22 A, 22 B at the replicated front and rear bumper 14 A, 16 A, respectively due to protrusion of the bumpers 14 , 16 .
- Deeper undercuts 22 C exist at the replicated wheel wells 12 A shown in the object 10 A in FIG. 2 due to protrusion of the vehicle body portion 17 above the wheel wells 12 A.
- the object 10 A is formed from only the single plastic sheet 18 , and has a contoured outer surface 23 A, and an opposite, contoured inner surface 23 B that defines a cavity 23 C.
- the flexible mold 20 is mounted to a base 24 in a manner described in greater detail herein.
- the base 24 has a base surface 26 that is planar.
- the undercut 22 A of the formed sheet 18 (shown in FIG. 3 ) formed by a protruding portion 28 A of the flexible mold 20 forms a first angle A 1 relative to the base surface 26 . Because the undercut 22 A is parallel with the base surface 26 , the first angle A 1 is 0 degrees when measured in a clockwise manner (left to right in FIG. 4 ) from the base surface 26 , or 180 degrees when measured in a counterclockwise manner (right to left in FIG. 4 ) from the base surface 26 .
- a protruding portion 28 B of the flexible mold 22 causes the undercut 22 B in the formed sheet 18 (shown in FIG. 3 ) that has a similar angle A 2 .
- the force F applied to remove the mold 20 from the cavity 23 C formed in the object 10 A in FIG. 13 is perpendicular to the base surface 26 , such as a downward direction shown in FIGS. 4 and 13 .
- the force F thus forms a second angle A 3 relative to the base surface 26 that is 90 degrees as shown in FIG. 4 .
- withdrawal of such a mold past the undercuts 22 A. 22 B, 22 C would be impossible.
- the method 100 enables the use of the flexible mold 20 that is of a flexible material such as silicone.
- the flexible mold 20 has an inner surface 30 defining a cavity 32 , and has an outer surface 34 .
- the flexible mold 20 is formed as described herein so that the outer surface 34 has a contoured shape that is complementary to and mates with the formed shape of the object 10 A.
- the outer surface 34 of the flexible mold 20 is in contact with and is coextensive with the inner surface 23 B of the object 10 A (shown in FIG. 3 ) prior to withdrawal of the flexible mold 20 from the object 10 A.
- the outer surface 34 is also substantially identical to the contoured shape 35 of the outer surface of the article 10 (shown in FIG. 1 ).
- FIG. 5 shows a rigid core 36 that is mounted on the base 24 .
- the rigid core 36 fits within the cavity 32 of the flexible mold 20 as is apparent in FIGS. 11 and 12 .
- the rigid core 36 is shown with hidden lines in FIG. 4 , and is best shown in FIGS. 5 and 11 .
- FIG. 5 shows that the base 24 has a series of openings 40 , only some of which are numbered in FIG. 5 .
- Each of the openings 40 extends entirely through the thickness of the base 24 , from the surface 26 to an opposing surface 42 .
- the openings 40 extend around the rigid core 36 on the base 24 .
- a casing 44 creates a manifold 46 extending from a vacuum source (V) 48 to the openings. Accordingly, the vacuum source 48 can apply a vacuum at the surface 26 through the openings 40 .
- V vacuum source
- FIGS. 6-8 illustrate how the flexible mold 20 of FIG. 4 is made.
- the method 100 may include making the flexible mold 20 according to the steps 102 - 114 , or the method may begin with a pre-made flexible mold 20 made according to the steps 102 - 114 .
- step 102 includes creating a female mold 50 that is then used to create the flexible mold 20 , which is a male mold.
- Step 102 includes sub-step 104 , placing the article 10 into a container 52 .
- mold material 54 for the female mold 50 is then poured or otherwise placed into the container 52 around the article 10 .
- FIG. 6 shows the mold material 54 poured over the article 10 to create the female mold 50 .
- Clay 51 may be placed under the article, between the wheels 12 and from bumper 14 to bumper 16 to prevent mold material 54 from going under the article 10 when poured into the container 52 .
- the mold material 54 may be a two-part silicone material.
- a cover 53 shown in FIG. 8
- a portion 55 of the container 52 that was previously on the bottom of the container 52 , as shown in FIG. 6 is then removed to reveal the mold 50 , as shown in FIG. 7 .
- the article 10 and any clay 51 thereunder is removed from the container 52 in sub-step 108 , leaving a void 56 having a shape of the article 10 , as partially shown in FIG. 7 .
- the female mold 50 is now complete.
- FIG. 8 shows the gap 58 already filled with mold material 60 for the flexible mold 20 , per the subsequent step 112 , pouring mold material 60 for the flexible mold 20 into the gap 58 .
- the mold material 60 may be silicone.
- the resulting flexible mold 20 has an outer surface 34 (best shown in FIG. 4 ) with a contoured shape that is the same as the contoured shape of the outer surface 23 A of the article 10 as a result of forming the female mold 50 around the article 10 as described with respect to FIG. 6 .
- step 114 the flexible mold 20 is separated from the female mold 50 by withdrawing the base 24 and rigid core 36 from the container 52 and flexing the mold 20 out of the female mold 50 .
- step 116 the flexible mold 20 is again placed on the rigid core 36 which is supported on the base 24 , as best shown in FIGS. 4 and 11 . More specifically, the rigid core 36 is placed in the cavity 32 of the flexible mold 20 .
- the plastic sheet 18 is then prepared for vacuum forming.
- the plastic sheet may be polyethylene terephthalate (PTEG), Acrylonitrile butadiene styrene (ABS), Polypropylene (PP), thermoplastic, or another polymeric material suitable for vacuum forming.
- the plastic sheet 18 is clamped to an oven tray 60 .
- FIG. 9 shows an oven tray 60 with clamps 62 that can be tightened to secure the plastic sheet 18 .
- the oven tray 60 could be sandwiched between an upper frame and a lower frame, each of which may be rectangular similar to the over tray 60 .
- the clamps 62 could then clamp the frames together to secure the over tray and sheet 18 between the frames. Any suitable arrangement to secure the sheet 18 relative to the oven tray 60 can be used.
- the oven tray 60 with the plastic sheet 18 clamped thereto is then moved at least partially into an entrance 66 of an oven 64 in step 120 as indicated by the directional arrow B.
- the plastic sheet 18 is then heated in the oven 64 in step 122 .
- the oven tray 60 and plastic sheet 18 are removed from the oven 64 in step 124 , as indicated by arrow C.
- the predetermined amount of time may be selected to ensure that the plastic sheet 18 reaches a predetermined temperature required for vacuum forming.
- a timer and/or temperature sensors may be used to monitor heating of the sheet 18 . Movement of the oven tray 60 into and out of the oven 64 could be done manually or could be automated. If the movement is automated, a robotic arm (not shown) could support and move the oven tray 60 . A person skilled in the art would readily understand the ability of a robotic arm to move the oven tray 60 into and out of the oven 64 .
- the flexible mold 20 is then raised into contact with the plastic sheet 18 in step 126 by moving the base 24 with the rigid core 36 and flexible mold 20 mounted thereon upward toward the sheet 18 as indicated by directional arrow D in FIG. 10 .
- the tray 60 is held in position either manually or by a robotic arm. Alternatively, the base 24 could remain stationary and the tray 60 could be moved toward the flexible mold 20 to place the plastic sheet 18 into contact with the flexible mold 20 .
- FIG. 11 show the plastic sheet 18 in contact with the flexible mold 20 .
- the base 24 is continued to be moved toward the sheet 18 until the sheet 18 pulls around the flexible mold 20 , and the vacuum 48 is applied in step 128 .
- the vacuum 48 is in fluid communication with the plastic sheet 18 through the casing 44 and the series of openings 40 . Accordingly, the vacuum 48 helps to pull the plastic sheet 18 against the entire outer surface 34 of the flexible mold 20 to conform the plastic sheet 18 to the contoured shape of the outer surface 34 .
- the plastic sheet 18 is then cooled in step 130 to allow the formed shape of the plastic sheet 18 to become permanent. Cooling may be with an air source, such as a fan 70 shown in FIG. 11 , or the plastic sheet 18 may be cooled passively simply by waiting a predetermined amount of time until the plastic sheet 18 reaches a predetermined temperature, such as ambient temperature, as may be determined by temperature sensors.
- the formed shape of the plastic sheet 18 is shown in FIG. 12 .
- step 132 the rigid core 36 is withdrawn from the cavity 32 in the flexible mold 20 as shown by the directional arrow E in FIG. 12 . Due to the undercuts 22 A, 22 B, 22 C (shown in FIG. 2 ), the flexible mold 20 will tend to be retained by the plastic sheet 18 during removal of the rigid core 36 . With the rigid core 36 removed, the flexible mold 20 can more easily flex inward relative to the inner surface 23 B of the inner cavity 23 C of the plastic sheet 18 in step 134 , in which the flexible mold 20 is withdrawn from the plastic sheet 18 . Withdrawing the flexible mold 20 from the plastic sheet 18 in step 134 is accomplished by applying force F to the flexible mold 20 which need be in only a single direction as shown in FIG. 13 .
- the force F is at 90 degrees in the embodiment shown, but may be at a different angle with respect to the base surface 26 in other embodiments, dependent on the angle of the undercut(s) of the flexible mold of the particular article to be replicated. Because the mold 20 is flexible, it flexes past the undercuts 22 A, 22 B, 22 C of the plastic sheet 18 . Arrows G 1 and G 2 in FIG. 13 represent the direction of inward movement of the protruding portions 28 A, 28 B when the mold 20 flexes past the undercuts 22 A, 22 B when the force F is applied in the direction shown.
- Excess material of the plastic sheet 18 can then be trimmed from a perimeter P of the formed shape of the plastic sheet 18 in step 136 .
- the perimeter P is shown in FIG. 3 .
- the excess material is represented by the portions 74 in FIG. 13 .
- the flexible mold 20 can be reused to vacuum form additional objects 10 A according to the steps 116 - 136 of the method 100 .
- the flexible mold 20 is less expensive than rigid molds typically required for an injection molding process that would be used for forming an article with undercuts.
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- Engineering & Computer Science (AREA)
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- Moulds For Moulding Plastics Or The Like (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
Abstract
A method of vacuum forming an object includes heating a plastic sheet. After heating the plastic sheet, a vacuum is applied to pull the sheet against an outer surface of a flexible mold so that the plastic sheet has a formed shape that conforms to a contoured shape of the outer surface of the flexible mold. A rigid core is withdrawn from a cavity in the flexible mold. The flexible mold is then withdrawn from the plastic sheet by applying force to the flexible mold in a single direction, thereby causing flexing of the flexible mold past the undercut. An apparatus for vacuum forming a plastic sheet includes the flexible mold.
Description
- This application is a divisional of and claims the benefit of priority to U.S. patent application Ser. No. 14/557,516 filed on Dec. 2, 2014, which is hereby incorporated by reference in its entirety.
- The present teachings generally include a method of vacuum forming an object and an apparatus for vacuum forming an object.
- Vacuum forming is a process by which a plastic sheet is heated and then formed to the shape of a die by applying a vacuum to draw the sheet against the surface of the object. The die must then be withdrawn. Objects suitable for vacuum forming on a unitary rigid die have heretofore been limited to those that do not have undercuts, as an undercut prevents withdrawal of the die from the formed sheet without damage to the formed sheet. Alternatively, a complex, costly die with sliding die portions would be required to allow removal of the sheet.
- A method of vacuum forming an object includes heating a plastic sheet. After heating the plastic sheet, a vacuum is applied to conform pull the plastic sheet to a contoured shape of an outer surface of a flexible mold so that the plastic sheet has a formed shape that includes an undercut. Typically, such an undercut would cause a die lock condition. Vacuum forming of an object to achieve such a formed shape was therefore not an option. However, under the method disclosed herein, a rigid core is withdrawn from a cavity in the flexible mold. The flexible mold is then withdrawn from the plastic sheet by applying force to the flexible mold in a single direction, thereby causing flexing of the flexible mold past the undercut. Because the mold is flexible, the plastic sheet is formed to replicate the object, including the undercut. Thus, objects with undercuts that previously required more costly processes, such as a complex die assembly with slides, or injection molding, can instead be vacuum formed.
- An apparatus for forming an object from a plastic sheet includes a mold having an inner surface defining a cavity and having an outer surface that has a contoured shape. A rigid core is configured to fit within the cavity. A vacuum source is positioned to vacuum form the plastic sheet to the outer surface of the mold to form the object having a formed shape, including an undercut, that conforms to the contoured shape of the mold. The formed shape includes an undercut. The mold is flexible, allowing the mold to be withdrawn from the plastic sheet past the undercut by applying force in a single direction after the rigid core is withdrawn from the cavity.
- The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the best modes for carrying out the present teachings when taken in connection with the accompanying drawings.
-
FIG. 1 is a schematic illustration in perspective view of an article to be replicated that is a scale model of a pickup truck to be replicated. -
FIG. 2 is a schematic illustration in perspective view of a vacuum-formed plastic sheet replicating the scale model ofFIG. 1 . -
FIG. 3 is a schematic illustration in another perspective view of the vacuum-formed plastic sheet ofFIG. 2 . -
FIG. 4 is a schematic illustration in side view of a flexible mold supported on a rigid core (shown in hidden lines) and on a base. -
FIG. 5 is a schematic illustration in perspective view of the rigid core supported on the base ofFIG. 4 . -
FIG. 6 is a schematic illustration in perspective view of a container containing the article ofFIG. 1 in mold material. -
FIG. 7 is a schematic illustration in plan view of the container ofFIG. 6 with the base suspending the rigid core above a female mold formed inFIG. 6 . -
FIG. 8 is a schematic cross-sectional illustration taken at lines 8-8 inFIG. 7 of the rigid core suspended above the female mold formed inFIG. 6 and with mold material poured in a gap to create the flexible mold ofFIG. 4 . -
FIG. 9 is a schematic illustration in perspective view of the plastic sheet clamped to an oven tray and an oven into which the tray is inserted and removed. -
FIG. 10 is a schematic illustration in perspective view of the plastic sheet positioned above the mold assembly and base ofFIG. 4 and with a vacuum source connected to the base. -
FIG. 11 is a schematic illustration in cross-sectional view of the plastic sheet vacuum formed to the flexible mold ofFIG. 4 and showing a cooling fan. -
FIG. 12 is a schematic illustration in cross-sectional view of the rigid core withdrawn from the flexible mold. -
FIG. 13 is a schematic illustration in cross-sectional view of the flexible mold flexing to move past undercuts in the vacuum formed sheet. -
FIG. 14 is a flow diagram of a method of vacuum forming an object. - Referring to the drawings, wherein like reference numbers refer to like components throughout the views,
FIG. 1 shows anarticle 10 to be replicated by amethod 100 described herein and represented in the flow diagram ofFIG. 14 . Thearticle 10 is a scale model of a pickup truck. It should be appreciated that thearticle 10 is only one example embodiment of an article that can be replicated by themethod 100, and themethod 100 can be applied to replicate other articles. More specifically, themethod 100 is particularly useful for replicating an article that has an undercut that creates a die lock condition that makes a conventional vacuum forming process with a unitary rigid die unusable. As used herein, an “undercut” is an angle of a portion of the outer surface of the formed object relative to a base on which a mold for the object is mounted that makes it impossible to remove the mold from the formed object by applying only a force in a single direction to the mold. For example, thearticle 10 ofFIG. 1 haswheel wells 12 over tire andwheel assemblies 13, afront bumper 14 and arear bumper 16, all of which result in undercuts in a vacuum formedplastic sheet 18 formed over aflexible mold 20 of thearticle 10, as shown inFIG. 11 . Theobject 10A formed from theplastic sheet 18 has undercuts 22A, 22B at the replicated front andrear bumper bumpers wheel wells 12A shown in theobject 10A inFIG. 2 due to protrusion of thevehicle body portion 17 above thewheel wells 12A. As shown inFIGS. 2 and 3 , theobject 10A is formed from only thesingle plastic sheet 18, and has a contouredouter surface 23A, and an opposite, contouredinner surface 23B that defines acavity 23C. - As shown in
FIG. 4 , theflexible mold 20 is mounted to abase 24 in a manner described in greater detail herein. Thebase 24 has abase surface 26 that is planar. The undercut 22A of the formed sheet 18 (shown inFIG. 3 ) formed by a protrudingportion 28A of theflexible mold 20 forms a first angle A1 relative to thebase surface 26. Because the undercut 22A is parallel with thebase surface 26, the first angle A1 is 0 degrees when measured in a clockwise manner (left to right inFIG. 4 ) from thebase surface 26, or 180 degrees when measured in a counterclockwise manner (right to left inFIG. 4 ) from thebase surface 26. A protrudingportion 28B of the flexible mold 22 causes the undercut 22B in the formed sheet 18 (shown inFIG. 3 ) that has a similar angle A2. The force F applied to remove themold 20 from thecavity 23C formed in theobject 10A inFIG. 13 is perpendicular to thebase surface 26, such as a downward direction shown inFIGS. 4 and 13 . The force F thus forms a second angle A3 relative to thebase surface 26 that is 90 degrees as shown inFIG. 4 . In a traditional vacuum forming process with a single, integral, non-flexible (i.e., rigid) mold, withdrawal of such a mold past theundercuts 22A. 22B, 22C would be impossible. - The
method 100 enables the use of theflexible mold 20 that is of a flexible material such as silicone. As best shown inFIG. 12 , theflexible mold 20 has aninner surface 30 defining acavity 32, and has anouter surface 34. Theflexible mold 20 is formed as described herein so that theouter surface 34 has a contoured shape that is complementary to and mates with the formed shape of theobject 10A. In other words, theouter surface 34 of theflexible mold 20 is in contact with and is coextensive with theinner surface 23B of theobject 10A (shown inFIG. 3 ) prior to withdrawal of theflexible mold 20 from theobject 10A. Theouter surface 34 is also substantially identical to thecontoured shape 35 of the outer surface of the article 10 (shown inFIG. 1 ). -
FIG. 5 shows arigid core 36 that is mounted on thebase 24. Therigid core 36 fits within thecavity 32 of theflexible mold 20 as is apparent inFIGS. 11 and 12 . Therigid core 36 is shown with hidden lines inFIG. 4 , and is best shown inFIGS. 5 and 11 .FIG. 5 shows that thebase 24 has a series ofopenings 40, only some of which are numbered inFIG. 5 . Each of theopenings 40 extends entirely through the thickness of thebase 24, from thesurface 26 to an opposingsurface 42. Theopenings 40 extend around therigid core 36 on thebase 24. As shown inFIG. 11 , acasing 44 creates a manifold 46 extending from a vacuum source (V) 48 to the openings. Accordingly, thevacuum source 48 can apply a vacuum at thesurface 26 through theopenings 40. -
FIGS. 6-8 illustrate how theflexible mold 20 ofFIG. 4 is made. Themethod 100 may include making theflexible mold 20 according to the steps 102-114, or the method may begin with a pre-madeflexible mold 20 made according to the steps 102-114. First,step 102 includes creating afemale mold 50 that is then used to create theflexible mold 20, which is a male mold. Step 102 includes sub-step 104, placing thearticle 10 into acontainer 52. Insub-step 106,mold material 54 for thefemale mold 50 is then poured or otherwise placed into thecontainer 52 around thearticle 10.FIG. 6 shows themold material 54 poured over thearticle 10 to create thefemale mold 50.Clay 51 may be placed under the article, between thewheels 12 and frombumper 14 tobumper 16 to preventmold material 54 from going under thearticle 10 when poured into thecontainer 52. Themold material 54 may be a two-part silicone material. Once themold material 54 is set, a cover 53 (shown inFIG. 8 ) is placed on top of theopen container 52 inFIG. 6 , and thecontainer 52 is inverted relative to its position during steps 102-106, as shown inFIGS. 7 and 8 . Aportion 55 of thecontainer 52 that was previously on the bottom of thecontainer 52, as shown inFIG. 6 , is then removed to reveal themold 50, as shown inFIG. 7 . Thearticle 10 and anyclay 51 thereunder is removed from thecontainer 52 insub-step 108, leaving a void 56 having a shape of thearticle 10, as partially shown inFIG. 7 . Thefemale mold 50 is now complete. - Next, the
method 100 proceeds to suspending therigid core 36 above thefemale mold 50 in thecontainer 52 instep 110 so that agap 58 exists between thefemale mold 50 and therigid core 36.FIG. 8 shows thegap 58 already filled withmold material 60 for theflexible mold 20, per thesubsequent step 112, pouringmold material 60 for theflexible mold 20 into thegap 58. Themold material 60 may be silicone. The resultingflexible mold 20 has an outer surface 34 (best shown inFIG. 4 ) with a contoured shape that is the same as the contoured shape of theouter surface 23A of thearticle 10 as a result of forming thefemale mold 50 around thearticle 10 as described with respect toFIG. 6 . - Next, in
step 114, theflexible mold 20 is separated from thefemale mold 50 by withdrawing thebase 24 andrigid core 36 from thecontainer 52 and flexing themold 20 out of thefemale mold 50. Next, instep 116, theflexible mold 20 is again placed on therigid core 36 which is supported on thebase 24, as best shown inFIGS. 4 and 11 . More specifically, therigid core 36 is placed in thecavity 32 of theflexible mold 20. - The
plastic sheet 18 is then prepared for vacuum forming. The plastic sheet may be polyethylene terephthalate (PTEG), Acrylonitrile butadiene styrene (ABS), Polypropylene (PP), thermoplastic, or another polymeric material suitable for vacuum forming. Instep 118, theplastic sheet 18 is clamped to anoven tray 60.FIG. 9 shows anoven tray 60 withclamps 62 that can be tightened to secure theplastic sheet 18. Optionally, theoven tray 60 could be sandwiched between an upper frame and a lower frame, each of which may be rectangular similar to the overtray 60. Theclamps 62 could then clamp the frames together to secure the over tray andsheet 18 between the frames. Any suitable arrangement to secure thesheet 18 relative to theoven tray 60 can be used. Theoven tray 60 with theplastic sheet 18 clamped thereto is then moved at least partially into anentrance 66 of anoven 64 instep 120 as indicated by the directional arrow B. Theplastic sheet 18 is then heated in theoven 64 instep 122. After a predetermined amount of time in theoven 64, theoven tray 60 andplastic sheet 18 are removed from theoven 64 instep 124, as indicated by arrow C. The predetermined amount of time may be selected to ensure that theplastic sheet 18 reaches a predetermined temperature required for vacuum forming. A timer and/or temperature sensors may be used to monitor heating of thesheet 18. Movement of theoven tray 60 into and out of theoven 64 could be done manually or could be automated. If the movement is automated, a robotic arm (not shown) could support and move theoven tray 60. A person skilled in the art would readily understand the ability of a robotic arm to move theoven tray 60 into and out of theoven 64. - With the
plastic sheet 18 sufficiently heated, theflexible mold 20 is then raised into contact with theplastic sheet 18 instep 126 by moving the base 24 with therigid core 36 andflexible mold 20 mounted thereon upward toward thesheet 18 as indicated by directional arrow D inFIG. 10 . Thetray 60 is held in position either manually or by a robotic arm. Alternatively, thebase 24 could remain stationary and thetray 60 could be moved toward theflexible mold 20 to place theplastic sheet 18 into contact with theflexible mold 20.FIG. 11 show theplastic sheet 18 in contact with theflexible mold 20. Thebase 24 is continued to be moved toward thesheet 18 until thesheet 18 pulls around theflexible mold 20, and thevacuum 48 is applied instep 128. Thevacuum 48 is in fluid communication with theplastic sheet 18 through thecasing 44 and the series ofopenings 40. Accordingly, thevacuum 48 helps to pull theplastic sheet 18 against the entireouter surface 34 of theflexible mold 20 to conform theplastic sheet 18 to the contoured shape of theouter surface 34. Theplastic sheet 18 is then cooled instep 130 to allow the formed shape of theplastic sheet 18 to become permanent. Cooling may be with an air source, such as afan 70 shown inFIG. 11 , or theplastic sheet 18 may be cooled passively simply by waiting a predetermined amount of time until theplastic sheet 18 reaches a predetermined temperature, such as ambient temperature, as may be determined by temperature sensors. The formed shape of theplastic sheet 18 is shown inFIG. 12 . - Next, in
step 132, therigid core 36 is withdrawn from thecavity 32 in theflexible mold 20 as shown by the directional arrow E inFIG. 12 . Due to the undercuts 22A, 22B, 22C (shown inFIG. 2 ), theflexible mold 20 will tend to be retained by theplastic sheet 18 during removal of therigid core 36. With therigid core 36 removed, theflexible mold 20 can more easily flex inward relative to theinner surface 23B of theinner cavity 23C of theplastic sheet 18 instep 134, in which theflexible mold 20 is withdrawn from theplastic sheet 18. Withdrawing theflexible mold 20 from theplastic sheet 18 instep 134 is accomplished by applying force F to theflexible mold 20 which need be in only a single direction as shown inFIG. 13 . The force F is at 90 degrees in the embodiment shown, but may be at a different angle with respect to thebase surface 26 in other embodiments, dependent on the angle of the undercut(s) of the flexible mold of the particular article to be replicated. Because themold 20 is flexible, it flexes past the undercuts 22A, 22B, 22C of theplastic sheet 18. Arrows G1 and G2 inFIG. 13 represent the direction of inward movement of the protrudingportions mold 20 flexes past the undercuts 22A, 22B when the force F is applied in the direction shown. - Excess material of the
plastic sheet 18 can then be trimmed from a perimeter P of the formed shape of theplastic sheet 18 instep 136. The perimeter P is shown inFIG. 3 . The excess material is represented by theportions 74 inFIG. 13 . With theobject 10A now completed. Theflexible mold 20 can be reused to vacuum formadditional objects 10A according to the steps 116-136 of themethod 100. Theflexible mold 20 is less expensive than rigid molds typically required for an injection molding process that would be used for forming an article with undercuts. - While the best modes for carrying out the many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims.
Claims (20)
1. An apparatus for forming an object from a plastic sheet comprising:
a mold having an inner surface defining a cavity and having an outer surface; wherein the outer surface has a contoured shape;
a rigid core configured to fit within the cavity;
a vacuum source positioned to vacuum form the plastic sheet to the outer surface of the mold to form the object having a formed shape that conforms to the contoured shape of the mold, the formed shape including an undercut; and
wherein the mold is flexible, allowing the mold to be withdrawn from the plastic sheet past the undercut by applying force in a single direction after the rigid core is withdrawn from the cavity.
2. The apparatus of claim 1 , further comprising:
a base on which the rigid core is secured;
wherein the base has a series of openings extending around the rigid core; and wherein the vacuum source is in fluid communication with the series of openings.
3. The apparatus of claim 2 , wherein the base has a surface on which the rigid core is secured; and wherein each opening of the series of openings extends through the base from the surface on which the rigid core is secured to an opposite surface of the base.
4. The apparatus of claim 2 , wherein the series of openings completely surround the rigid core.
5. The apparatus of claim 2 , wherein the base has a surface on which the rigid core is secured; wherein the undercut forms a first angle relative to the surface of the base; wherein the force is applied to the mold to withdraw the mold from the plastic sheet past the undercut at a second angle relative to the base; and wherein the second angle is different than the first angle.
6. The apparatus of claim 5 , wherein the second angle is a 90 degree angle such that the force is applied perpendicular to the base.
7. The apparatus of claim 1 , further comprising:
a base having a base surface on which the rigid core is secured; and
wherein the force is applied perpendicular to the base surface.
8. The apparatus of claim 7 , wherein the undercut is parallel to the base surface.
9. The apparatus of claim 1 , wherein a protruding portion of the mold forms the undercut.
10. The apparatus of claim 9 , wherein the object is a scale model of a vehicle having a wheel and a bumper, and the undercut is at the wheel or at the bumper.
11. The apparatus of claim 1 , wherein the mold is silicone.
12. The apparatus of claim 1 , wherein the outer surface of the flexible mold is configured to be coextensive with an inner surface of the object.
13. The apparatus of claim 1 , wherein an outer surface of the object is substantially identical to the contoured shape of the outer surface of the flexible mold.
14. An apparatus for forming an object from a plastic sheet comprising:
a mold having an inner surface defining a cavity and having an outer surface; wherein the outer surface has a contoured shape;
a rigid core configured to fit within the cavity;
a vacuum source positioned to vacuum form the plastic sheet to the outer surface of the mold to form the object having a formed shape that conforms to the contoured shape of the mold, the formed shape including an undercut;
a base having a surface on which the rigid core is secured;
wherein the base has a series of openings completely surrounding the rigid core; wherein each opening of the series of openings extends through the base from the surface on which the core is secured to an opposite surface of the base; wherein the vacuum source is in fluid communication with the series of openings; and
wherein the mold is flexible, allowing the mold to be withdrawn from the plastic sheet past the undercut by applying force in a single direction after the rigid core is withdrawn from the cavity.
15. The apparatus of claim 14 , wherein the force is applied perpendicular to the base surface.
16. The apparatus of claim 15 , wherein the undercut is parallel to the base surface.
17. The apparatus of claim 14 , wherein a protruding portion of the mold forms the undercut.
18. The apparatus of claim 17 , wherein the object is a scale model of a vehicle having a wheel and a bumper, and the undercut is at the wheel or at the bumper.
19. The apparatus of claim 14 , wherein the outer surface of the flexible mold is configured to be coextensive with an inner surface of the object.
20. The apparatus of claim 14 , wherein an outer surface of the object is substantially identical to the contoured shape of the outer surface of the flexible mold.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US16/039,882 US20180319073A1 (en) | 2014-12-02 | 2018-07-19 | Method of vacuum forming an object using a flexible mold and an apparatus for vacuum forming an object |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US14/557,516 US10059050B2 (en) | 2014-12-02 | 2014-12-02 | Method of vacuum forming an object using a flexible mold and an apparatus for vacuum forming an object |
US16/039,882 US20180319073A1 (en) | 2014-12-02 | 2018-07-19 | Method of vacuum forming an object using a flexible mold and an apparatus for vacuum forming an object |
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US14/557,516 Division US10059050B2 (en) | 2014-12-02 | 2014-12-02 | Method of vacuum forming an object using a flexible mold and an apparatus for vacuum forming an object |
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US20180319073A1 true US20180319073A1 (en) | 2018-11-08 |
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US14/557,516 Active 2037-02-21 US10059050B2 (en) | 2014-12-02 | 2014-12-02 | Method of vacuum forming an object using a flexible mold and an apparatus for vacuum forming an object |
US16/039,882 Abandoned US20180319073A1 (en) | 2014-12-02 | 2018-07-19 | Method of vacuum forming an object using a flexible mold and an apparatus for vacuum forming an object |
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US14/557,516 Active 2037-02-21 US10059050B2 (en) | 2014-12-02 | 2014-12-02 | Method of vacuum forming an object using a flexible mold and an apparatus for vacuum forming an object |
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US (2) | US10059050B2 (en) |
CN (1) | CN105643910B (en) |
DE (1) | DE102015119912B4 (en) |
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GB2575242B (en) * | 2018-05-30 | 2022-11-23 | Acell Ind Ltd | Vacuum forming process |
EP3685936A1 (en) | 2019-01-22 | 2020-07-29 | Bajerke Flaig Ruf GbR | Mould with elastic separating layer |
US11938670B2 (en) * | 2021-09-01 | 2024-03-26 | GM Global Technology Operations LLC | Powder coated vacuum formed articles |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3378888A (en) * | 1965-10-19 | 1968-04-23 | Holley Plastics Company | Structure for vacuum forming of thermoplastic material on undercut flexible molds |
Family Cites Families (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3898315A (en) * | 1971-02-25 | 1975-08-05 | Kent Plastics | Method for removing molds from articles with undercuts |
JPS5814292B2 (en) * | 1977-12-20 | 1983-03-18 | 三洋電機株式会社 | Method for manufacturing synthetic resin containers |
DE3640710A1 (en) | 1986-11-28 | 1988-06-09 | Incel Zeki | Process for vacuum forming thermoplastic material and mould for carrying out the process and process for further processing mouldings produced by vacuum forming |
JP3236196B2 (en) | 1995-08-10 | 2001-12-10 | 吉田化学株式会社 | Vacuum forming mold and vacuum forming method using the same |
NO313942B1 (en) | 1998-04-08 | 2002-12-30 | Isola As | Use of a cam plate as a backing pad |
JP4765599B2 (en) | 2005-12-12 | 2011-09-07 | トヨタ車体株式会社 | Vacuum forming method and apparatus |
NL1036702A1 (en) | 2008-04-15 | 2009-10-19 | Asml Holding Nv | Diffraction elements for alignment targets. |
CN101590692A (en) | 2009-05-20 | 2009-12-02 | 安徽鲲鹏装备模具制造有限公司 | A kind of vacuum forming technique of pressing sky |
JP5383442B2 (en) | 2009-11-13 | 2014-01-08 | 本田技研工業株式会社 | Molding equipment |
CN203792699U (en) | 2014-03-20 | 2014-08-27 | 上海珐伊玻璃钢船艇有限公司 | Quick molding device for irregular surface of yacht interior |
-
2014
- 2014-12-02 US US14/557,516 patent/US10059050B2/en active Active
-
2015
- 2015-11-18 DE DE102015119912.2A patent/DE102015119912B4/en active Active
- 2015-11-30 CN CN201510854638.6A patent/CN105643910B/en active Active
-
2018
- 2018-07-19 US US16/039,882 patent/US20180319073A1/en not_active Abandoned
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3378888A (en) * | 1965-10-19 | 1968-04-23 | Holley Plastics Company | Structure for vacuum forming of thermoplastic material on undercut flexible molds |
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US10059050B2 (en) | 2018-08-28 |
DE102015119912B4 (en) | 2022-05-25 |
DE102015119912A1 (en) | 2016-06-02 |
US20160151958A1 (en) | 2016-06-02 |
CN105643910B (en) | 2018-12-28 |
CN105643910A (en) | 2016-06-08 |
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