WO1990014209A2 - Moulding of thermoplastic sheet materials - Google Patents
Moulding of thermoplastic sheet materials Download PDFInfo
- Publication number
- WO1990014209A2 WO1990014209A2 PCT/GB1990/000809 GB9000809W WO9014209A2 WO 1990014209 A2 WO1990014209 A2 WO 1990014209A2 GB 9000809 W GB9000809 W GB 9000809W WO 9014209 A2 WO9014209 A2 WO 9014209A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- mould
- sheet material
- liquid
- sheet
- fluid
- Prior art date
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B23/00—Re-forming shaped glass
- C03B23/02—Re-forming glass sheets
- C03B23/023—Re-forming glass sheets by bending
- C03B23/025—Re-forming glass sheets by bending by gravity
- C03B23/0258—Gravity bending involving applying local or additional heating, cooling or insulating means
-
- 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
- B29C51/42—Heating or cooling
- B29C51/421—Heating or cooling of preforms, specially adapted for thermoforming
- B29C51/424—Heating or cooling of preforms, specially adapted for thermoforming using a heated fluid
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B18/00—Shaping glass in contact with the surface of a liquid
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B23/00—Re-forming shaped glass
- C03B23/02—Re-forming glass sheets
- C03B23/023—Re-forming glass sheets by bending
- C03B23/025—Re-forming glass sheets by bending by gravity
- C03B23/0256—Gravity bending accelerated by applying mechanical forces, e.g. inertia, weights or local forces
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B23/00—Re-forming shaped glass
- C03B23/02—Re-forming glass sheets
- C03B23/023—Re-forming glass sheets by bending
- C03B23/035—Re-forming glass sheets by bending using a gas cushion or by changing gas pressure, e.g. by applying vacuum or blowing for supporting the glass while bending
Definitions
- the present invention relates to moulding of thermoplastic sheet materials, that is materials which soften and become mouldable upon application of heat.
- the invention is particularly applicable to glass but may be used with thermoplastic plastics materials.
- Laminate sheet materials are often required to be moulded to shape such that the material is deformed to a three dimensional topography whilst maintaining an approximate uniformity in thickness. This is particularly important when the product • is required to be transparent and produce little optical distortion.
- Conventional methods of producing such forms include vacuum moulding, sag bending and press bending. These processes require a mould and care must be taken to avoid abrading the surface of the material.
- During the formation of the three dimensional product from a flat sheet local stretching and compaction will occur in the material producing a tendency to tear or buckle. This limits the complexity and accuracy of the forming process.
- the conventional methods of forming to a mould do not provide a simple method of controlling such local movement.
- the present invention provides a means of moulding thermoplastic sheet materials whilst maintaining control on the local deformation.
- a method of moulding a thermoplastic sheet material is characterised by; floating the sheet material on a liquid, the density of the liquid being greater than that of the sheet material; maintaining the liquid at a temperature at which the sheet material is plastic; and bringing a mould progressively into engagement with the sheet material so that the sheet material is deformed to the shape of the mould.
- a mould is filled with liquid, the density of the liquid being greater than that of the sheet material and the temperature being maintained at a temperature at which the sheet material is plastic; the sheet material is floated on the liquid so that the periphery of the sheet material sealingly engages the periphery of the mould and the liquid is permitted to drain from the mould in controlled manner, so that the thermoplastic sheet is drawn down into engagement with the surface of the mould.
- the mould is submerged in a bath of the liquid maintained at an appropriate temperature whilst the sheet material floats on the surface.
- the moulding process is accomplished by raising the mould so that the lip engages the floating sheet and is sealed with respect thereto, the mould then being raised in a controlled manner.
- a drain in the base. of the mould allows liquid to escape as the sheet material deforms to the shape of the mould above the level of the liquid in the mould whilst still being supported by the liquid above the submerged portions of the mould.
- the interface between the sheet material and the mould surface will in general be lubricated by the liquid which will be retained in the gap by capillary action provided the surfaces are wetted by the liquid. This action should prevent abrasion of the surface.
- the "working" liquid must be more dense than the laminate sheet so that the sheet will float. As the liquid is removed during the moulding process air pressure acting on the sheet material will deform the material to the mould. The largest pressure differential that acts on the sheet material depends on the vapour pressure and temperature of the liquid and a suitable liquid should be chosen accordingly. Furthermore the maximum height of liquid that can be supported by atmospheric pressure depends on the density; thus with mercury this height is 76 cm at 1 atmosphere whilst with water this height is approximately 10 m. Thus, if the liquid is drained by gravity then the density is very important in terms of the lift of the mould. Generally the liquid should be as dense as possible, be inert and have a high boiling point. Liquid metals such as mercury and tin and some alloys such as Woods metal could be suitable as might some heavy oils and solvents such as carbon tetrabromide.
- the sheet material is floated on the liquid, the liquid having a density greater than that of the sheet material and being maintained at a termperature at which the sheet material is plastic and a mould is lowered onto the sheet material, so that the buoyancy of the sheet material will deform the sheet material so that it conforms to the surface of the mould.
- the sheet material which might be precut to a plan shape, is floated on a bath of liquid, maintained at the correct temperature for moulding, and so heating the sheet material by contact with the liquid.
- the material is registered relative to the mould and the mould submerged at a predetermined rate, below the surface of the liquid.
- the sheet material floating on the liquid is moulded to the form of the mould, by the buoyant forces acting on the material.
- Additional moulding force may be achieved by providing rapid downward impetus to the mould once submerged to ensure good contact of the material with the mould surface. Such force will depend on the area of the mould, the restriction on motion of the liquid and the speed of motion.
- Sound waves may also be introduced into the liquid to provide an impressed additional oscillating force to the buoyant force acting on the sheet material.
- the sheet material may be maintained in contact with the mould after forming by suction between the mould and the material.
- This suction being achieved by ensuring atmospheric pressure cannot be exerted at the mould/material interface.
- the release of the material from the mould will be achieved by allowing the pressure at the mould/material interface to rise and so reduce the suction.
- a method of moulding a thermoplastic sheet material is characterised by supporting the sheet material, directing a jet of fluid onto the sheet material, the fluid being maintained at a temperature at which the sheet material is plastic, and controlling the jet so that the sheet material is deformed to the required shape.
- the position and direction of the nozzle are preferably automatically controlled to follow a prescribed pattern.
- the pattern being determined to give an acceptable moulding process and to minimise stretching and buckling.
- the automatic control being accomplished by means of a computer or microprocessor.
- the support for the sheet material is in the form of a mould underlaying the sheet and registered to it so that the stream of fluid leaving the nozzle progressively forms the sheet against the mould in accordance with the spatial pattern followed by the nozzle.
- the pressure of the pumped fluid might be altered to vary the force exerted by the fluid on the sheet material.
- the sheet material might be supported by a ring frame and the fluid stream is then used to form the material to shape in the areas where it is not underlayed. Reproduction is achieved by having a repeatable process and constant material properties.
- the fluid material may be gas or liquid.
- the force of the fluid acting on the sheet material will depend on the density, flow rate and velocity. It is also intended that the fluid will partially or wholly heat the sheet material to facilitate deforming to shape. The specific heat of the fluid is therefore important. Variable parameters which might be used to facilitate the forming process are flow rate, temperature, velocity, nozzle shape.
- an apparatus for moulding thermoplastic sheet material is characterised by a container for liquid, means for maintaining the liquid at a temperature at which the sheet material is plastic, a mould and means for moving the mould into engagement with the sheet material when floated on the surface of the liquid.
- Figure 1 illustrates a method of forming glass sheet in accordance with the present invention
- Figures 2A, 2B and 2C illustrate stages of the forming process illustrated in Figure 1;
- Figure 3 illustrated a view similar to Figure 2B, but with different mould configuration
- FIG. 4 illustrates a modification to the apparatus used in
- Figure 5 illustrates an alternative method of forming glass sheet, in accordance with the present invention
- FIG. 6A and 6B illustrate stages of the method illustrated in Figure 5;
- Figure 7 illustrates an alternative method of forming glass sheet, in accordance, with the present invention.
- Figure 8 illustrates a modification to the method illustrated in Figure 7.
- the apparatus 10 comprises a bath 11 filled with molten tin 12 which is maintained at an appropriate temperature by a heater 13.
- a mould 14 is suspended belov; the surface of the molten tin 12 with a drain 15 let into sump 16.
- a sheet of glass 17 is floated on the surface of the molten tin 12 and is maintained in a plastic condition by heat transfer therefrom.
- Lifting frame 18 attached to the mould 14 is connected to a hoist 19 supported on a gantry 20.
- the mould 14 is lifted by means of hoist 19 until the lip 21 of the mould 14 engages the glass sheet 17
- Figures 2 ⁇ , 2B and 2C show the glass sheet 17 at various stages through the forming process.
- Figure 2A shows the inital stage in which the lip 21 of the mould 14 is in contact with the glass sheet 17 before deformation has occurred.
- Figure 2B shows the process at an intermediate stage while Figure 2C shows the glass sheet 17 fully conforming with the mould 14.
- the glass sheet 17 is in a
- SUBSTITUTE SHEET position where the surface of the mould 14 is steep.
- the glass sheet 17 at position A is fully supported by the mould 14 whilst at position B it is supported by the molten tin 12.
- the amount of deformation and stretching of the glass sheet 17 in the locality of position C will depend upon the time available for the deformation to occur and how much of the surface force is transmitted through the glass sheet 17.
- the time available for deformation and stretching may be controlled by controlling the rate at v/hich molten tin 12 drains from the mould 14, the rate being slower for steeper surfaces of the mould 14.
- the surface force is primarily related to the viscosity and hence to shear rate of the glass sheet 17.
- a cooling channel 26 is provided in the lip 25 of mould 14.
- This cooling channel 26 is adapted to be connected to a cooling water supply.
- a heating strip 28 is also provided in lip 25 of mould 14 adjacent the surface D which is engaged by the sheet material during moulding.
- the heating strip 28 may be used to melt the frozen metal and permit removal of the moulded glass sheet 17 from the mould 14.
- a sheet of glass 30 is floated upon a bath 35 of molten tin 31.
- the molten tin 31 is heated to the required forming temperature which in turn heats the glass sheet 30 by contact.
- a mould 32 is mounted above the glass sheet 30 and is attached to a hoist 33 enabling the mould 32 to be lowered onto the glass sheet 30.
- the glass sheet 30 is registered against lugs 34 attached to the mould 32.
- the buoyant force acting on the glass sheet 30 forces the glass sheet 30 to conform v/ith the mould 32.
- the trapped gas and/or molten tin 31 in volume 39 is expelled through hole 38.
- the process is controlled by the rate of introducing the mould 32 into contact with the glass sheet 30 and the temperature of operation.
- Figure 6A illustrates the mould 32 partly engaged v/ith the glass sheet 30 floating on molten tin 31.
- the buoyancy force so exerted causes the glass sheet 30 to deform towards the mould. Air and molten tin 31 caught in the volume above the glass sheet v/ill be expelled and drained by breather hole 38.
- FIG. 6B illustrates the glass sheet material 30 fully
- a robotic arm 51 holds an adjustable nozzle 52 above glass sheet material 53 supported on mould 55. Mould 55 is inclined so that liquid will drain from the surface to sump 56. Molten tin 57 initially in sump 56 is pumped via heater 58 to nozzle 52. The nozzle 52 is moved spatially and directionally by robotic arm 51 in a pattern v/hich forces the glass sheet 53 to conform to mould 55. The temperature and velocity of the stream of molten tin 57 leaving the nozzle 52 and controlled to facilitate the forming process.
- This apparatus may be used in the following manner:-
- a gentle diffuse spray of hot molten tin 57 is first sprayed onto the surface of the glass sheet 53 to allow the sheet to reach its moulding temperature;
- the jet is finally narrowed and a high pressure jet directed by the robot arm 51 to areas requiring further forming to the mould.
- the temperature of the molten tin 57 may also be increased at this stage.
- Figure 8 illustrates an alternative means of supporting the sheet material 53.
- Glass sheet 53 is held in ring frame 62 at an angle so that liquid will drain from the surface to sump 56, nozzle 52 supported by robotic arm 51 directs molten tin 57 at a temperature and velocity that might be varied to suit the process.
- the glass sheet material 53 is progressively deformed to desired shape by the action of the stream of molten tin 57 impinging upon the surface. Repeatability is ensured by having accurate repeatable action of the nozzle 52, pump 59 and heater 58, and by uniformity of material properites of the glass sheet 53.
- SUBSTITUTE SHEET liquid in the bath 11 may alternatively be reduced or the bath 11 itself lowered.
- the sheet material 17 is over-sized and the periphery which is engaged by the lip 21 of the mould 14 will be trimmed after moulding.
- the sheet material 17 may be cut to size prior to moulding and suitable registering formations may be provided on the lip 21 of the mould 14 to accurately align the cut sheet 17 v/ith the mould 14.
- suitable registering formations may be provided on the lip 21 of the mould 14 to accurately align the cut sheet 17 v/ith the mould 14.
- a recess may be provided around the inner periphery of the lip 21 of the 'mould 14 in which the sheet material 17 will be located v/hen the mould 14 is raised to engage the sheet 17.
- glass sheet is moulded using molten tin
- other molten metals for example lead, or other substances with suitable melting points, for example fused salts, may be used.
- the method is also applicable to other molten metals, for example lead, or other substances with suitable melting points, for example fused salts, may be used.
- the method is also applicable to other molten metals, for example lead, or other substances with suitable melting points, for example fused salts, may be used.
- suitable melting points for example fused salts
- thermoplastic materials for example plastics materials where mercury or lov/ melting point alloys may be used as the liquid media.
- a flux may be provided as an interlayer between the sheet material and molten metal, in order to avoid oxidation.
Abstract
Description
Claims
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB8911868.1 | 1989-05-24 | ||
GB8911866.5 | 1989-05-24 | ||
GB898911866A GB8911866D0 (en) | 1989-05-24 | 1989-05-24 | Liquid suction forming |
GB8911867.3 | 1989-05-24 | ||
GB898911867A GB8911867D0 (en) | 1989-05-24 | 1989-05-24 | Float forming of sheet materials |
GB898911868A GB8911868D0 (en) | 1989-05-24 | 1989-05-24 | Jet forming of sheet materials |
Publications (2)
Publication Number | Publication Date |
---|---|
WO1990014209A2 true WO1990014209A2 (en) | 1990-11-29 |
WO1990014209A3 WO1990014209A3 (en) | 1991-01-10 |
Family
ID=27264490
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/GB1990/000809 WO1990014209A2 (en) | 1989-05-24 | 1990-05-24 | Moulding of thermoplastic sheet materials |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP0473668A1 (en) |
JP (1) | JPH04506053A (en) |
WO (1) | WO1990014209A2 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6306237B1 (en) * | 1995-11-28 | 2001-10-23 | Roy D. Wemyss | Lamination of surfaces using pressurized liquid |
ES2211251A1 (en) * | 2000-07-11 | 2004-07-01 | R.C.N. Engineering, S.R.L. | Procedure and apparatus for the plastic deformation of glass plates. (Machine-translation by Google Translate, not legally binding) |
FR2869256A1 (en) * | 2004-04-21 | 2005-10-28 | Lanxess Deutschland Gmbh | PROCESS FOR SHAPING PLASTIC PLATES |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2014112485A1 (en) * | 2013-01-17 | 2014-07-24 | 旭硝子株式会社 | Method for manufacturing molded body and method for manufacturing glass molded body |
Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1482789A (en) * | 1921-03-30 | 1924-02-05 | Eugene C Gmelin | Method of making glass letters |
FR981363A (en) * | 1948-12-30 | 1951-05-25 | Process for the deformation of thermoplastic materials | |
FR1433969A (en) * | 1964-05-22 | 1966-04-01 | Basf Ag | Process for the production of molded articles from expanded thermoplastic materials |
US3460929A (en) * | 1966-12-14 | 1969-08-12 | Westinghouse Electric Corp | Method and apparatus for the manufacture of glass envelopes |
DE2044047A1 (en) * | 1970-09-05 | 1972-03-09 | Pressed Steel Fisher Ltd | Forming sheet or plate material |
JPS613725A (en) * | 1984-06-18 | 1986-01-09 | Nissan Shatai Co Ltd | Molding method of resin material and device thereof |
JPS63293034A (en) * | 1987-05-25 | 1988-11-30 | Takashi Mori | Transparent capsule and manufacture thereof |
EP0303710A1 (en) * | 1987-02-23 | 1989-02-22 | Namba Press Works Co., Ltd. | Method of forming thermoplastic fabric |
-
1990
- 1990-05-24 EP EP19900908296 patent/EP0473668A1/en not_active Withdrawn
- 1990-05-24 WO PCT/GB1990/000809 patent/WO1990014209A2/en not_active Application Discontinuation
- 1990-05-24 JP JP50774990A patent/JPH04506053A/en active Pending
Patent Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1482789A (en) * | 1921-03-30 | 1924-02-05 | Eugene C Gmelin | Method of making glass letters |
FR981363A (en) * | 1948-12-30 | 1951-05-25 | Process for the deformation of thermoplastic materials | |
FR1433969A (en) * | 1964-05-22 | 1966-04-01 | Basf Ag | Process for the production of molded articles from expanded thermoplastic materials |
US3460929A (en) * | 1966-12-14 | 1969-08-12 | Westinghouse Electric Corp | Method and apparatus for the manufacture of glass envelopes |
DE2044047A1 (en) * | 1970-09-05 | 1972-03-09 | Pressed Steel Fisher Ltd | Forming sheet or plate material |
JPS613725A (en) * | 1984-06-18 | 1986-01-09 | Nissan Shatai Co Ltd | Molding method of resin material and device thereof |
EP0303710A1 (en) * | 1987-02-23 | 1989-02-22 | Namba Press Works Co., Ltd. | Method of forming thermoplastic fabric |
JPS63293034A (en) * | 1987-05-25 | 1988-11-30 | Takashi Mori | Transparent capsule and manufacture thereof |
Non-Patent Citations (2)
Title |
---|
PATENT ABSTRACTS OF JAPAN, Volume 10, No. 151 (M-483) (2208), 31 May 1986, & JP,A,61003725 (Nitsusan Shiyatai K.K.) 9 January 1986 see Abstract; figures * |
PATENT ABSTRACTS OF JAPAN, Volume 13, No. 118 (M-806) (3466), 23 March 1989, & JP,A,63293034 (Takashi Mori) 30 November 1988 see Abstract; figures * |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6306237B1 (en) * | 1995-11-28 | 2001-10-23 | Roy D. Wemyss | Lamination of surfaces using pressurized liquid |
ES2211251A1 (en) * | 2000-07-11 | 2004-07-01 | R.C.N. Engineering, S.R.L. | Procedure and apparatus for the plastic deformation of glass plates. (Machine-translation by Google Translate, not legally binding) |
FR2869256A1 (en) * | 2004-04-21 | 2005-10-28 | Lanxess Deutschland Gmbh | PROCESS FOR SHAPING PLASTIC PLATES |
Also Published As
Publication number | Publication date |
---|---|
EP0473668A1 (en) | 1992-03-11 |
JPH04506053A (en) | 1992-10-22 |
WO1990014209A3 (en) | 1991-01-10 |
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