Abstract: The present invention is a twinsheet door which includes a first door portion and a second door portion connected to the first door portion. The twinsheet door of the present invention is manufactured using a thermoforming process, during which a vacuum shapes the first door portion and the second door portion such that one or more closed sections are created when the first door portion is thermally bonded to the second door portion and simultaneously a vacuum is applied to form the first door portion and said second door portion. The closed section formed between the first door portion and second door portion provides additional strength and rigidity to the twinsheet door. Additionally, the forming of the closed section between the first door portion and the second door portion and the bonding between the first door portion and second door portion is achieved during a single manufacturing process.

Abstract: The present invention is a twinsheet door which includes a first door portion and a second door portion connected to the first door portion. The twinsheet door of the present invention is manufactured using a thermoforming process, during which a vacuum shapes the first door portion and the second door portion such that one or more closed sections are created when the first door portion is thermally bonded to the second door portion and simultaneously a vacuum is applied to form the first door portion and said second door portion. The closed section formed between the first door portion and second door portion provides additional strength and rigidity to the twinsheet door. Additionally, the forming of the closed section between the first door portion and the second door portion and the bonding between the first door portion and second door portion is achieved during a single manufacturing process.

Abstract: A unitary plastic appliance door is produced by thermoforming an outer door panel and an inner door liner and joining them together in a unitary apparatus. The inner door liner is formed of sheet plastic on a male mold member and is then positioned over a female mold member mounted alongside the male mold member. The outer door panel is formed from a second sheet of plastic in the female mold member and then the inner door liner is registered with the formed outer door panel in the female mold member and is joined thereto to form the appliance door.

Abstract: Apparatus is provided for thermoforming a unitary plastic appliance door by thermoforming an outer door panel and an inner door liner and joining them together in a unitary apparatus. The apparatus includes a press with first and second platens, a male and a female mold member attached to the first platen and shaped to the contour of the outer door panel and the inner door liner respectively. A movable shuttle box is mounted on the second platen and a first plug assist member is located in the shuttle box. The shuttle box and first plug assist member are movable on the second platen into vertical alignment with either the male or female mold member. A transportation device is positioned between the first and second platens and is operable for transporting first and second plastic sheets into thermoforming posture with the male and female molds respectively. A second plug assist member is located for movement into and out of proximity with the female mold member.