WO2002062550B1 - Processes for forming plastic, apparatuses for forming plastic, and articles made therefrom - Google Patents

Processes for forming plastic, apparatuses for forming plastic, and articles made therefrom

Info

Publication number
WO2002062550B1
WO2002062550B1 PCT/US2002/003298 US0203298W WO02062550B1 WO 2002062550 B1 WO2002062550 B1 WO 2002062550B1 US 0203298 W US0203298 W US 0203298W WO 02062550 B1 WO02062550 B1 WO 02062550B1
Authority
WO
WIPO (PCT)
Prior art keywords
plastic
male
female
molds
particulate
Prior art date
Application number
PCT/US2002/003298
Other languages
French (fr)
Other versions
WO2002062550A9 (en
WO2002062550A1 (en
Inventor
Panfilo M Dinello
Miguel A Linares
Lynn E Cargill
Robin L Pointer
Paul A Haines
Original Assignee
3Dm Technologies Inc
Panfilo M Dinello
Miguel A Linares
Lynn E Cargill
Robin L Pointer
Paul A Haines
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
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=27402274&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2002062550(B1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Priority to GB0320695A priority Critical patent/GB2388336C/en
Priority to DK02713536.7T priority patent/DK1360047T4/en
Priority to DE60238820T priority patent/DE60238820D1/en
Priority to JP2002562539A priority patent/JP4284495B2/en
Priority to EP02713536.7A priority patent/EP1360047B2/en
Priority to SI200230933T priority patent/SI1360047T2/en
Priority to US10/239,039 priority patent/US8221668B2/en
Priority to ES02713536.7T priority patent/ES2359047T5/en
Priority to CA002437221A priority patent/CA2437221C/en
Priority to NZ527461A priority patent/NZ527461A/en
Priority to AU2002245383A priority patent/AU2002245383B2/en
Priority to AT02713536T priority patent/ATE494121T1/en
Priority to BR0207257-2A priority patent/BR0207257A/en
Application filed by 3Dm Technologies Inc, Panfilo M Dinello, Miguel A Linares, Lynn E Cargill, Robin L Pointer, Paul A Haines filed Critical 3Dm Technologies Inc
Publication of WO2002062550A1 publication Critical patent/WO2002062550A1/en
Publication of WO2002062550B1 publication Critical patent/WO2002062550B1/en
Priority to HK04101094.9A priority patent/HK1058331A1/en
Publication of WO2002062550A9 publication Critical patent/WO2002062550A9/en
Priority to US13/550,314 priority patent/US20120282429A1/en

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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1228—Joining preformed parts by the expanding material
    • B29C44/1233—Joining preformed parts by the expanding material the preformed parts being supported during expanding
    • 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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/18—Slush casting, i.e. pouring moulding material into a hollow mould with excess material being poured off
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/52—Heating or cooling
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/08—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles using several expanding or moulding steps
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
    • 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
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B29C69/004—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore making articles by joining parts moulded in separate cavities, said parts being in said separate cavities during said joining
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/467—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements during mould closing
    • 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
    • B29C2791/001—Shaping in several steps
    • 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
    • B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
    • B29C33/06—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means using radiation, e.g. electro-magnetic waves, induction heating
    • 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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/08—Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder
    • B29C41/10—Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder by fluidisation
    • 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
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/20—Inserts
    • B29K2105/206—Meshes, lattices or nets
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25—Solid
    • B29K2105/251—Particles, powder or granules
    • 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
    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/002—Panels; Plates; Sheets
    • 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
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3008—Instrument panels
    • 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
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3011—Roof linings
    • 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
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3041—Trim panels
    • 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
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • B29L2031/3079—Cockpits, canopies
    • 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
    • B29L2031/44—Furniture or parts thereof
    • B29L2031/441—Countertops
    • 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
    • B29L2031/7178—Pallets
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/40—Weight reduction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23—Sheet including cover or casing
    • Y10T428/233—Foamed or expanded material encased

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Abstract

Process and apparatus (10) for forming plastics by heating an open mold (12) and contacting the open mold (12) with plastic particulate material (16) held within a container (14) to form a melted skin on the mold (12), and resulting articles made therefro. The mold (12) is provided with a carrier (18), which may include heating and cooling lines for achieving a desired mold temperature. Single skin molded articles may be multi-layered with or without paint on the surface. Multiple skin moled articles may include sandwiched layers of plastic filler or expandable foam filled centers, with or without various inserts or reinforcements.

Claims

AMENDED CLAIMS[received by the International Bureau on 12 August 2002 (12.08.02); original claims 1-25 replaced by amended claims 1-25; (8 pages)]
1. A process for foππiπg plastic into a predetermined shape from a plastic particulate material having a melting point, said process comprising: providing an open mold made of a material selected from the group consisting of aluminum, aluminum alloys, kirksite, metals, ceramics, cermets, high temperature plastics, foπnable heat resistant materials and combinations thereof, said mold being formed into a predetermined shape with at least a face portion to impart a desired shape; heating at least the face portion of the open mold to an elevated temperature of from about 100°C to about 865DC such that the mold is at a higher temperature than the melting point of the plastic particulate material; contacting the open mold to the plastic particulate material while the plastic particulate is at least at room temperature for a dwell time period of from about one second to about 30 minutes, said dwell time period being pre-selected to melt the plastic particulate into a skin of a desired thickness of from about 0.001 cm to about 3.0 cm prior to ceasing contact of the open mold with the plastic particulate.
2. The process of claim 1, further comprising cooling the mold to release the resulting article.
3. The process of claim 1, further comprising providing a second heated mold, said second heated mold being complementary to the first heated mold, and said molds being adapted to be placed together to form a double skinned article.
4. The process of claim 3, further comprising a step of placing a reinforcement between the first and second heated molds, such that the reinforcement is embedded between the heated double skins.
5. The process of claim 1, wherein the step of contacting the open mold to a plastic particulate material is accomplished by contacting with a polyolefin.
39
6. A process for forming plastic into a predetermined shape from a plastic particulate material having a melting point, said process comprising: providing male and female complementary molds made of a material selected from the group consisting of aluminum, aluminum alloys, kirksite, metals, ceramics, cermets, high temperature plastics, formable heat resistant materials and combinations thereof, said molds being formed into a predetermined shape with at least a face portion on each of said complementary male and female molds to impart a desired shape; heating said male and female molds at least on their face portions to an elevated temperature of from about 100°C to about 865°C such that the mold is at a temperature above the melting point of the plastic particulate; contacting the male and female molds with the plastic particulate while the plastic particulate is at least at room temperature for a dwell time period of from about 1 second to about 30 minutes, said dwell time period being pre-selected to melt the plastic particulate into a molded skin of a plastic article having a skin of a desired thickness of from about 0.001 cm to about 3.0 cm prior to ceasing contact with the plastic particulate; bringing together the' complementary face portions of the heated male and female molds to adhere the two skins of plastic articles to each other such that an article is formed having a molded surface on both sides.
7. The process of claim 6, further comprising a step of placing a reinforcement between said male and female molds prior to the step of bringing together the male and female molds and adhering the skins together.
8. The process of claim 6, wherein the plastic particulate at least at room temperature is at an elevated temperature under the melting point of the plastic particulate.
9. The process of claim 6, wherein said heating of the molds is accomplished by heating them to an elevated temperature of from about 160"C to about 220«C.
10. The process of claim 6, wherein the dwell time period is from about three to about 10 minutes.
40
11. The process of claim 6, wherein tbe step of bringing together the male and female molds is accomplished by spacing them apart.
12. A process for forming a plastic composite into a predetermined shape from a plastic particulate material and a plastic filler material, each plastic material having a respective melting point, said process comprising: providing male and female complementary molds made of a material selected from the group consisting of aluminum, aluminum alloys, kirksite, metals, ceramics, cermets, high temperature plastics, formable heat resistant materials and combinations thereof, said molds being formed into a predetermined shape with at least a face portion on each of said complementary male and female molds to impart a desired shape; heating at least the face portions of the male and female complementary molds to an elevated temperature of from about 13Q°C to about 865DC which is above the melting points of the respective plastic particulate material and the plastic filler material; contacting the face portion of the complementary molds to the plastic particulate material resulting in two melted plastic skins on the surfaces of the male and female molds, said contacting occurring while the plastic particulate is at least at room temperature for a dwell time period of from about 1 second to about 30 minutes, said dwell time period being pre-selected to melt the plastic particulate into a layer of a desired thickness prior to ceasing contact with the plastic particulate; spacing apart the two complementary male and female molds from one another at a predetermined distance and placing plastic filler material between the male and female molds such that tbe plastic filler material may be sandwiched between the male and female molds to form a double skinned composite having a plastic filler material between the two skins, with an overall predetermined thickness of the composite; and cooling at least one of the male and female molds to loosen and remove the entire resultant double skinned, filled composite article.
13. The process of claim 12, wherein the step of heating the molds is accomplished by elevating the temperature to about 160°C to about 220°C.
41
14. The process of claim 12, further comprising a step of placing a reinforcement between said male and female molds prior to tbe step of bringing together the male and female molds and adhering the skins together.
15. The process of claim 12, further comprising inserting an expandable plastic filler material between the heated molds after the skins have been formed to form an expanded plastic center.
16. A process for forming a plastic composite into a predetermined shape from a plastic particulate material and an expandable plastic filler material, each having a respective melting point, said process comprising: providing male and female complementary molds made of a material selected from the group consisting of aluminum, aluminum alloys, kirksite, metals, ceramics, cermets, high temperature plastics, formable heat resistant materials and combinations thereof, said molds being formed into a predetermined shape with at least a face portion on each of said complementary male and female molds to impart a desired shape; providing a means for heating the male and female complementary molds to an elevated temperature of from about 100°C to about 865DC which is above the melting points of the respective plastic particulate material and the expandable plastic filler material, such that contacting the complementary molds to the plastic particulate material will result in a melted plastic layer on the surface contacted; heating said complementary male and female molds by said heating means at least on their face portions to a temperature above the melting point of the plastic particulate, and then contacting the face portion of the two molds with plastic particulate while the plastic particulate is at least at room temperature for a dwell time period preselected to melt the plastic particulate into a skin layer of a desired thickness on the face portion, prior to ceasing contact with the plastic particulate; and holding the two complementary male and female molds apart from one another at a predetermined distance and placing expandable plastic filler between the two heated complementary molds such that the expandable plastic filler material is sandwiched and expanded between the male and female molds to a thickness determined by the distance the molds are apart.
17. An apparatus for forming plastic into a predetermined shape from a plastic particulate material having a melting point, said apparatus comprising: an open mold made of a material selected from the group consisting of aluminum, aluminum alloys, kirksite, metals, ceramics, cermets, high temperature plastics, formable heat resistant materials and combinations thereof, said mold being formed into a predetermined shape with at least a face portion to impart the desired shape; said complementary male and female molds being beatable at least on their face portions to a temperature above the melting point of the plastic particulate, for contacting with the plastic particulate while the plastic particulate is at least at room temperature for a dwell time period preselected to melt the plastic particulate into a layer of a desired thickness prior to ceasing contact with the plastic particulate.
18. An apparatus for forming plastic into a predetermined shape from a plastic particulate material having a melting point, said apparatus comprising: a pair of male and female complementary molds made of a material selected from the group consisting of aluminum, aluminum alloys, kirksite, metals, ceramics, cermets, high temperature plastics, formable heat resistant materials and combinations thereof, said molds being formed into a predetermined shape with at least a face portion on each of said complementary male and female molds to impart a desired shape; said complementary male and female molds being heatable at least on their face portions to a temperature above the melting point of the plastic particulate, for contacting with the plastic particulate while the plastic particulate is at least at room temperature for a dwell time period preselected to melt the plastic particulate into a layer of a desired thickness prior to ceasing contact with the plastic particulate.
19. An apparatus for forming a plastic composite into a predetermined shape from a plastic particulate material and a plastic filler material, each having a respective melting point, said apparatus comprising: a pair of male and female complementary molds made of a material selected from the group consisting of aluminum, aluminum alloys, kirksite, metals, ceramics, cermets, high temperature plastics, formable heat resistant materials and combinations thereof, said molds being formed into a predetermined shape with at least a face portion on each of said complementary male and female molds to impart a desired shape;
43 means for heating the male and female complementary molds to an elevated temperature of from about 100°C to about 865°C which is above the melting points of the respective plastic particulate material and tbe plastic filler material, such that contacting the heated complementary molds to the plastic particulate material results in a melted plastic skin layer on the surface contacted; said complementary male and female molds being heatable at least on their face portions to a temperature above the melting point of the plastic particulate, for contacting with the plastic particulate while the plastic particulate is at least at room temperature for a dwell time period preselected to melt the plastic particulate into a layer of a desired thickness prior to ceasing contact with the plastic particulate; and a spacer for holding the two complementary male and female molds apart from one another at a predetermined distance such that the plastic filler material may be sandwiched between the male and female molds to a thickness determined by the spacer.
20. An apparatus for forming a plastic composite into a predetermined shape from a plastic particulate material and an expandable plastic filler material, eacb having a respective melting point, said apparatus comprising: male and female complementary molds made of a material selected from the group consisting of aluminum, aluminum alloys, kirksite, metals, ceramics, cermets, high temperature plastics, formable heat resistant materials and combinations thereof, said molds being formed into a predetermined shape with at least a face portion on each of said complementary male and female molds to impart a desired shape; means for heating the male and female complementary molds to an elevated temperature of from about 100DC to about 865°C which is above the melting points of the respective plastic particulate material and the expandable plastic filler material, such that contacting the complementary molds to the plastic particulate material results in a melted plastic layer on the surface contacted; said complementary male and female molds being heatable at least on their face portions to a temperature above the melting point of the plastic particulate, for contacting with the plastic particulate while the plastic particulate is at least at room temperature for a dwell time period preselected to melt the plastic particulate into a layer of a desired thickness prior to ceasing contact with the plastic particulate; and a spacer for holding the two complementary male and female molds apart from one another at a predetermined distance such that the expandable plastic filler
44 material may be sandwiched and expanded between the male and female molds to a thickness determined by the spacer.
21. A plastic pick-up truck bed box for installing on the chassis of a pick- up truck, comprising: spaced apart male and female plastic skins, each being shaped over an open mold and both being adapted to fit onto the chassis of the pick-up truck, said male and female skins being formed of a polyolefinic material, each having a thickness of from about 0.001 cm to about 1.0 cm; a low density expandable plastic material sandwiched between said male and female skins, having a thickness of from about 1.0 cm to about 5.0 cm; a steel mesh reinforcement shaped like the molds for the male and female skins, said steel reinforcement being inserted between the male and female molds, embedded into and surrounded by the expandable plastic, such that the pick-up truck box is reinforced by the strength of the steel; and load rails inserted into the female mold prior to the expandable plastic material, said load rails being located at the bottom of the resulting truck box, being surrounded by the plastic skins and the expandable plastic, such that the plastic pick-up truck bed box is adapted for easy mounting onto a pick-up truck chassis.
22. A plastic industrial tabletop to be mounted on table legs, comprising: spaced apart male and female plastic skins, each being shaped over an open mold and both being adapted to fit onto table legs, said male and female skins being formed of a polyolefinic material, each having a thickness of from about 0.001 cm to about 1.0 cm; a low density expandable plastic material sandwiched between said male and female skins, having a thickness of from about 1.0 cm to about 5.0 cm; and a steel mesh reinforcement shaped like the molds for the male and female skins, said steel reinforcement being inserted between the male and female molds, embedded into and surrounded by the expandable plastic, such that the tabletop is reinforced by the strength of the steel.
45
23. A plastic airplane cockpit door, comprising: spaced apart male and female plastic skins, each being shaped over an open mold and both being adapted to fit into an aiφlane cockpit, said male and female skins being formed of a polyolefinic material, each having a thickness of from about 0-001 cm to about 1.0 cm; a low density expandable plastic material sandwiched between said male and female skins, having a thickness of from about 1.0 cm to about 5.0 cm; a sheet of evlar inserted between the male and female plastic skins and being encapsulated and surrounded by the expandable plastic material; and a steel mesh reinforcement shaped like the molds for the male and female skins, said steel reinforcement being inserted between the male and female molds, embedded into and surrounded by the expandable plastic, such that the aiφlane cockpit door is reinforced by the strength of the steel and made bullet-proof by the Kevlar sheet inclusion.
24. A plastic modular housing panel, comprising: spaced apart male and female plastic skins, each being shaped over an open mold and both being adapted to fit into together with other modular housing panels, said male and female skins being formed of a polyolefinic material, each having a thickness of from about 0.001 cm to about 1.0 cm; a low density expandable plastic material sandwiched between said male and female skins, having a thickness of from about 1.0 cm to about 5.0 cm; and thermally insulating material inserted between the male and female plastic skins and being encapsulated and surrounded by the expandable plastic material.
25. A lightweight plastic material handling pallet, comprising: paced apart male and female plastic skins, each being shaped over an open mold and both being adapted to support industrial material loads, said male and female skins being formed of a polyolefinic material, each having a thickness of from about 0.001 cm to about 1.0 cm; a low density expandable plastic material sandwiched between said male and female skins, having a thickness of from about 1.0 cm to about 5.0 cm; and steel cone reinforcements embedded into and surrounded by the expandable plastic material, said reinforcements located between the male and female molds, thereby lending strength and durability to the pallet.
46
PCT/US2002/003298 2001-02-05 2002-02-05 Processes for forming plastic, apparatuses for forming plastic, and articles made therefrom WO2002062550A1 (en)

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DK02713536.7T DK1360047T4 (en) 2001-02-05 2002-02-05 Process for forming plastic
NZ527461A NZ527461A (en) 2001-02-05 2002-02-05 Processes for forming plastic, apparatuses for forming plastic, and articles made therefrom
CA002437221A CA2437221C (en) 2001-02-05 2002-02-05 Processes for forming plastic, apparatuses for forming plastic, and articles made therefrom
JP2002562539A JP4284495B2 (en) 2001-02-05 2002-02-05 Plastic molding method, plastic molding apparatus, and parts made therefrom
EP02713536.7A EP1360047B2 (en) 2001-02-05 2002-02-05 Process for forming plastic
SI200230933T SI1360047T2 (en) 2001-02-05 2002-02-05 Process for forming plastic
US10/239,039 US8221668B2 (en) 2001-02-05 2002-02-05 Process for forming plastic, apparatuses for forming plastic, and articles made therefrom
ES02713536.7T ES2359047T5 (en) 2001-02-05 2002-02-05 Plastic shaping procedure
DE60238820T DE60238820D1 (en) 2001-02-05 2002-02-05 PROCESS FOR PRODUCING PLASTIC
GB0320695A GB2388336C (en) 2001-02-05 2002-02-05 Processes for forming plastic, apparatuses for forming plastic, and articles made therefrom
AT02713536T ATE494121T1 (en) 2001-02-05 2002-02-05 METHOD FOR PRODUCING PLASTIC
AU2002245383A AU2002245383B2 (en) 2001-02-05 2002-02-05 Processes for forming plastic, apparatuses for forming plastic, and articles made therefrom
BR0207257-2A BR0207257A (en) 2001-02-05 2002-02-05 Plastic forming process, plastic forming apparatus and articles made therefrom
HK04101094.9A HK1058331A1 (en) 2001-02-05 2004-02-16 Process for forming plastic
US13/550,314 US20120282429A1 (en) 2001-02-05 2012-07-16 Processes For Forming Plastic, Apparatuses For Forming Plastic, And Articles Made Therefrom

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US27032101P 2001-02-05 2001-02-05
US60/270,321 2001-02-05
US30087401P 2001-06-25 2001-06-25
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US60/346,336 2002-01-07

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