Abstract: In forming operations on plastic sheets, plates, strips, or tubes (particularly, having highly glossy surfaces) by molding or forming tools, the surface qualities, particularly the gloss, remains undamaged if; (a) the tool is maintained at a temperature in the thermoelastic state region of the plastic until disengagement of the plastic from the tool; and (b) the formed plastic is cooled at its rear side to below the softening temperature, and is disengaged from the forming tool while said tool is hot.

Abstract: Method for the production of heat resistant polyethyleneterephthalate containers by means of thermoforming with a longitudinal and radial direction stretching of a sheet (1) of unstretched amorphous polymer in a die (2) kept at a temperature of about 175.degree.-180.degree. C. The container is consolidated and extracted by a counterdie (4), cooled and provided with suction means. The containers thus are stable at sterilization temperature in boiling water and in steam at 130.degree. C.

Abstract: Thermoplastic layers are vacuum thermoformed to produce laminated structures by perforating all layers to be formed except the layer outermost from the mold. Thus, the non-perforated layer is attracted to the mold, serving as a diaphragm for the other layers or consolidating therewith to form the desired article.

Abstract: Laminated billets are made by extruding a plurality of sheets, cooling and stacking said sheets to form a stack, laminating a portion of said stack using radio frequency radiation, cutting out at least the laminated portion from the stack and returning the resulting individual webs to their respective sheet extrusion process.

Abstract: A laminate having at least one non-dielectrically heatable first material, (processable at an optimum starting temperature), and at least one dielectrically-heatable second material, (processable at a higher optimum finish temperature), is initially brought to its starting temperature. The dielectrically heatable second material is then heated to its finish temperature, by being subjected to radio frequency (RF) or microwave radiation at selected frequency(s). The laminate is then stretched so as to shape the laminate while the first material and second material are at or near to their optimum processing temperatures.

Abstract: For the production of decorative seams on dashboards or the like, molded of thermoplastic material by the deep-drawing method, or the like, a soft heated embossing die having a negative decorative seam is pressed briefly, at the instant of the deformation of the dashboard or the like, against the molding tool covered with the film. Elastic embossing cushions are glued into the molding tool, thereby providing that the decorative seam will have a convex curvature.

Abstract: A present invention is directed to an apparatus for PTP Pocket forming on a sheet which requires delicate care for handling. Combination of local and discriminate preparative heating of the pocket-regions of freshly unrolled sheets while leaving the rest of the sheet in a cooled state in a lattice structure, preliminarily expanding said regions up to about 70% of the volume of the recesses of the female die by pressing heated plugs to the region and supplying compressed-air to the expanded region. Details of the temperature control on various steps parts of the apparatus as well as a means for attaining virtually complete thermal equilibrium over the preparative heating station are also disclosed.

Abstract: A method of manufacturing hollow articles of thermoplastic materials. Initially, a compact blank, such as a tablet, a palette, a disk or the like, is formed by injection molding into a mold cavity. The blank may be composed of a plurality of layers which surround each other. Subsequently, the blank is compression-molded in the heated state to reduce its thickness and increase its surface area size. Finally, again in the heated state, the compressed blank is formed into a hollow article by a stretching and blow-molding operation. During each injection-molding step, the volume of the mold cavity is adjusted from a minimum volume to a maximum volume at a rate which corresponds to the rate of injection of the respective plastics material.

Abstract: A disposable container suitable for retaining liquids comprises two opposed container sections, each having a peripheral ring like flange about a recess with the flanges being sealed therebetween. The recesses of the opposed container sections define a common central cavity and the flanges include a throat opening into said cavity through which product within the cavity can be dispensed. The throat is at least partially defined by the opposed container flanges and each container section is of a thermoformable plastic material. These container sections are originally formed from flat strip packaging material having diecut side edges with the strip defining individual container body sections. A tapered neck portion of each body section accommodates dispensing of the contents and preferably a hot melt adhesive secures the opposed container sections.

Abstract: A method of molding oriented structural yarn/polymer matrix composite structural articles in which a preform of oriented yarn layers saturated with a resin is placed in a shape-defining mold, which is put in an enclosure, and subjected to heat and pressure to cure the resin, after which a cooling medium may be introduced. To enable the use of lightweight multi-part molds, and a mixture of pressure is distributed evenly, an internal liner is collapsed about the mold prior to curing. The process is extremely productive, and allows for accuracy and reproducibility through the use of real time temperature monitoring and closed loop feedback control.

Abstract: A method of forming relatively large objects, such as refrigerator liners, by a solid phase forming process from crystalline-type synthetic resins, such as polypropylene. The invention comprehends utilization of stretch forming, vacuum forming, and pressure forming techniques in combination with controlled heating of different portions of the billet to provide desired differential thicknesses in different portions of the liner. The invention further comprehends the provision of the liner with biaxial molecular orientation in portions thereof subject to shock impact forces.

Abstract: A deep drawing molding process for the formation of shaped plastic elements in which a certain thickness of the thermoplastic sheet to be formed is heated to the plastic flow state while an embossed or decorated outer side of the sheet is maintained at a temperature below the plastic state by means of a cooling air stream. The plastic element producted has an undamaged decorated side and improved wear properties such that it may be used in high ambient temperature applications, such as automobile dashboards, without cracking. The apparatus for heating and forming the plastic element includes a clamping frame to hold the sheet, a heating element disposed above the sheet, a molding box below the frame, which box is provided with inlets and outlets for cooling air and the application of vacuum, and a moldign tool also disposed above said frame, which is forced through said frame and against said sheet when a certain thickness of the sheet has been heated to the desired plastic flow temperature.

Abstract: A process for regulating the heating of a thermoplastic band used in a station for thermoforming upwardly open containers, the process being characterized in that, in a zone of the softened thermoplastic band, zone surrounded by a mesh of rigidified matter, the degree of deformation of this zone under the action of a predetermined mass is measured, the measured value of the degree of deformation is compared with a predetermined reference value corresponding to a good aptitude to thermoforming, and the heating of the band is regulated as a function of the value of deformation measured so that the deformation corresponds to the reference value.

Abstract: A web of molten thermoplastics material (4) from extruder die (3) is fed through a pair of temperature controlled rolls (5) having a gap (13) of width less than that of the web thickness leaving the extruder die (3) and is fed from the rolls (5) directly and continuously under uniform tension to a thermoforming machine (9) (10) as a formable web (6) of substantially uniform temperature through its thickness.

Abstract: An apparatus for, and a method of, heating a thermoplastic material in web form in readiness for forming three-dimensional objects therefrom in a thermo-forming process involves (a) advancing the web material intermittently through a heating zone on a belt conveyor without imposing thereon any mechanical stress-inducing physical constraints (such as may be applied by material gripping means), and (b) sweeping the web material with a series of hot air jets which are spaced apart in the direction movement of the material, which extend transversely across the width of the material, and which are reciprocated in that direction in a manner such as to ensure a uniform heating of the web material passing out of the heating zone to a thermo-forming apparatus.

Abstract: Cupola-shaped plastic pieces with a flat, unwarped rim can be produced from an equally large blank without trimming of the rim, by heating an optionally preheated plastic sheet by radiant heat. The radiant heat acts only on the area surrounded by the rim area until the area exposed to the radiant heat has reached a temperature just below the softening temperature of the plastic. Up to this point, the rim is left without tension, or at most a low clamping pressure is applied which allows a thermal movement of the rim. Then, but before the beginning of the forming, the clamping pressure is increased so that the rim is held tight. The radiation activity continues until the area exposed to the radiant heat has exceeded the softening temperature, the radiation activity is then stopped, and the area heated to the forming temperature is formed.

Abstract: A tubular article with a closed end is formed from a thermoformable polymer material, e.g. a high molecular weight saturated linear polyester such as polyethylene terephthalate, by forcing a punch (21) through the plane of a pre-heated and clamped sheet (13) of the polymer, centrally within an annular die (10) so as to draw the sheet into tubular form without exerting compressive stresses on the sheet between the punch and die, the punch being maintained at a temperature below the glass transition temperature of the polymer, e.g. by passing cooling fluid through internal passages (16), and being moved at a speed of at least 1/2 meter per second to effect the drawing. The punch head (21) may be convex or concave to produce a shaped closed end on the article, e.g. for making a pressure-resistant container, and the punch may co-operate with a shaped movable anvil (201) at the end or at an intermediate point in its stroke.

Abstract: A method for forming deep drawn highly oriented thin-walled thermoplastic articles including the steps of planarly supporting a sheet of at least partially crystalline thermoplastic polymeric material and establishing at least one differentially heated area within the sheet. The differentially heated area is to include an outer cool zone having a temperature range generally below the crystalline melt point of the thermoplastic material, a hot zone disposed within the outer zone having a temperature range generally above the crystalline melt point but below the complete melt point of the thermoplastic material, and an inner cool zone located centrally of the hot zone having a temperature range generally below the crystalline melt point of the thermoplastic material. The heated sheet is placed between a female mold unit and a forming mandrel with the inner cool zone generally axially aligned therewith.

Abstract: To produce a panel of variable thickness, a stratified assembly of a layer of fibers containing a non-polymerized binder and at least one cover sheet is placed between the mold and mold-backing of a molding press. The stratified assembly is caused to conform to the interior surface of the mold or mold-backing by forcing the cover sheet against the mold or mold-backing interior. Hot air is blown into the fiber layer from the mold surface opposite the cover sheet, into at least the region that will correspond to the area of greater thickness. The direction of the heated air is reversed after a period of time, the blowing of the air being maintained and adjusted in order to secure polymerization of the binder. At the same time, the portions of the panel corresponding to areas of lesser thickness, generally the edges of an acoustical panel, are cured (the binder polymerized) by contact heating means.

Abstract: The present invention relates to an improved plug or tool for use in the production of shaped articles from thermoplastic sheet materials. An important feature of the present invention is that the tool or plug comprises a body portion which incorporates one or more inserts which possess a thermal conductivity different from the thermal conductivity of the body portion.

Abstract: A method for double-side thermoforming opposite faces of a sheet of plastic is set forth. The method includes heating the sheet to a temperature within its transition range and forming one face of the sheet into the desired pattern by bringing a contour-forming first surface into contact with the face. After contact has been made, a pressure differential is imposed to cause the one face to be formed by and freeze-off to the contour of the first surface. After one face of the sheet has been formed, a second contour-forming surface is positioned adjacent to the other face of the plastic sheet. Producing a pressure differential between the opposite faces of the plastic sheet causes the other face to be formed by and freeze-off into the desired pattern imposed by the second contour-forming surface resulting in the desired plastic part. The present invention also includes a plastic part fashioned according to the aforesaid method.

Abstract: Disclosed is a process of making an oriented and heat set thermoformed hollow article of poly(ethylene terephthalate) so that the sidewalls of the articles resulting from the process have a density over 1.391 cc./gm. and an onset-of-shrinkage temperature over 105.degree. C. In the process, a sheet preheated to a temperature suitable for orientation is biaxially stretch thermoformed and then while the hollow article walls are still in contact with the mold walls, the article is raised to a higher heat setting temperature in the range of about 220-250.degree. C. thus heat setting the article, and while the article is still under restraint resisting shrinkage, quenching the sidewalls of the article to a temperature that will provide a shrinkage of less than about 5% by volume and the above onset-of-shrinkage temperature of at least about 105.degree. C.

Abstract: A tubular plastic container having a molecularly oriented sidewall portion is made by bringing the peripheral portion of a solid blank in engagement with the shoulder portion of a die, introducing the blank into a cavity of the die while compressing with a first and second plungers, such that in the former stage of the introduction, the speed is relatively low and the pressure is relatively high, and then the speed is increased at a controlled rate and the pressure is decreased, thereby forming a hollow molded piece, and then expanding the molded piece to bringing the sidewall portion thereof into contact with the inner surface of the cavity.

Abstract: A method of fabricating a custom denture using a preformed tooth arch and a custom formed denture base, attaching these units with a self polymerizing plastic, using a plasterless keying articulator in conjuction with an occlusal translator thereby completing the entire fabrication of a custom denture on the articulator without the conventional waxup, flasking, processing which is the present state of the art.

Abstract: The present invention relates to an improved plug or tool for use in the production of shaped articles from thermoplastic sheet materials. An important feature of the present invention is that the tool or plug comprises a body portion which incorporates one or more inserts which possess a thermal conductivity different from the thermal conductivity of the body portion.

Abstract: A shaped article such as a container of polyalkylene terephthalate resin is described. The shaped article includes a body portion in which the resin has an average crystallinity of at least about 20 percent. The shaped article is provided with the flange which adjoins the body portion of the article. At least part of the flange has an average crystallinity less than that of the body portion and preferably of not more than about 10 percent. Process and apparatus which may be employed in the manufacture of such an article are also described.

Abstract: This relates to the forming of containers and like hollow articles from sheets or webs of thermoplastic material. Two webs or sheets are simultaneously acted upon by way of a forming apparatus which includes a reciprocating clamp first cooperable with one outer platen and then the other in sequence wherein, while a first web or sheet is being formed within a plurality of mold cavities to define a plurality of hollow articles such as containers, the other sheet or web may be stripped from its respective mold set and a new sheet or a new portion of a sheet or web may be advanced into position for molding. The forming apparatus may be constructed in a manner wherein the web portions which are to be formed may be billowed away from the mold cavities as an initial step in the stretching and orientation of the thermoplastic material.

Abstract: A method for producing a hollow synthetic resin article, which comprises opening a split mold having an inner molding surface with a contour conforming to the configuration of the desired article, feeding a heated molding material of a thermoplastic synthetic resin in the form of a tube or two parallel-laid sheets into a space between the opposing mold members of the split mold, applying a negative pressure to vacuum suction holes provided in the molding surfaced and the parting surfaces of the split mold to vacuum-form the molding material, and while the negative pressure is being applied or after the application of the negative pressure is stopped, closing the mold to form the molding material into the final desired configuration.

Abstract: A re-sealable hollow body container is disclosed together with the method of making it. The container is made with a preformed neck from a flat piece of plastic sheet or film.

Abstract: A thin-wall deep drawn container having a molding depth vs. aperture caliber ratio of 2.0 or more, having a mean wall thickness of 0.1-0.6 mm at the sidewall and bottom of the hollow part and having a flange part of 1.4 mm or less in thickness at the aperture end can be produced from a thick sheet of a thermoplastic resin, preferably a crystalline plastic, having a thickness of 2 mm or more by plug-assist pressure forming.

Abstract: A method of and an apparatus for producing containers from thermoplastic sheet material are disclosed. The sheet material is heated to its plastic state and clamped at its periphery. Then a moulding die is advanced substantially normally towards and against the clamped heated sheet material. The moulding die has a temperature below the temperature of the heated clamped sheet material and is provided with a projecting peripheral portion and/or a recessed central portion directed towards the sheet material. By further advancing the moulding die by a predetermined amount against the sheet material, this is deformed and shaped into the desired container. A cooling air flow is directed against the clamped heated sheet material in a region thereof adjacent to the peripheral portion of the moulding die to avoid reduced wall thickness at the edge and corner regions of the container by excessive stretching of the sheet material. Thus, stable containers of uniform wall thickness may be produced.

Abstract: A process for the manufacture of articles from a thermoplastic of polyester or polyamide type, preferably of polyethylene terephthalate, the element consisting of an edge part which surrounds a body in an arrangement in which the latter is sunk relative to the edge part. The element is formed from a blank of mainly amorphous material or from a material having a crystallinity of less than 10%. The blank consists, for example, of a flat plate, a blank shell or the like. The body or parts thereof are shaped by stretching the blank until that material flows which is located within the material sections of the blank, which form the edge part in the element, the material stretched up to flowing in the body assuming a crystallinity of between 10% and 25%, while the crystallinity in the material in the edge part and in the unstretched parts retains its original value of less than 10%. At least the body of the element is expanded against warm mould walls until the final shape of the particular article is obtained.

Abstract: A shaped article such as a container of polyalkylene terephthalate resin is described. The shaped article includes a body portion in which the resin has an average crystallinity of at least about 20 percent. The shaped article is provided with the flange which adjoins the body portion of the article. At least part of the flange has an average crystallinity less than that of the body portion and preferably of not more than about 10 percent. Process and apparatus which may be employed in the manufacture of such an article are also described.

Abstract: A thermoplastic cylindrical clamp is manufactured by heating a flat sheet of thermoplastic material, thermoforming the softened sheet over a mold having two parallel and semicylindrical shapes with a narrow planar space between them and a coplanar flange surrounding, trimming the thermoformed sheet so the semicylinders are open at each end, locally heating the narrow planar portion between the semicylinders to the softening point, bending the softened portion so the semicylinders form a complete cylinder and cooling the part in the cylindrical shape.

Abstract: A method for molding a polycarbonate plastic sheet into a skylight dome or the like. A clamp frame is preheated to a first temperature. A polycarbonate plastic sheet is thereafter clamped around its perimeter in the preheated clamp frame and preheated to approximately the first temperature. The unclamped portion of the plastic sheet is heated to about 300.degree. by ovens to soften the plastic for forming. The softened plastic sheet is then subjected to forming by a pair of coacting peripheral heated molds to form steps and pushes in the plastic sheet immediately adjacent to the clamp frames. A vacuum is drawn over the center portion of the sheet to free-form a dome. The molds are separated and the formed article is removed from the heated clamp frame. The steps of preheating the plastic sheet perimeter in the heated clamp frame and heating of the peripheral molds prevents distortion of the flange area of the slylight dome and of the step and push areas of the dome.

Abstract: Disclosed is a container for storing product, a process and apparatus for making that container, a process and apparatus for drawing and blow forming plastic into a paperboard outer container and a process and apparatus for heat sealing a container. The container comprises a paperboard outer container and a plastic inner container which has been drawn and blow formed into the outer container. At the mouth of the container are horizontal plastic flanges which extend about the periphery of the container at least about 1/8 inch outwardly from the plastic inner container. Vertical flanges extend downwardly at least about 1/8 inch from the horizontal flanges. After product is placed in the container, the container is sealed by a heat sealable cover. A plastic overcap may be provided which engagedly fits around the container at its top.

Abstract: A method of producing a molded leather holster capable of holding the holstered item in the holster by friction or pressure due to the molding and which is capable of retaining its molded shape in the presence of moisture, the method comprising preparing a laminate of at least one layer of leather and a layer of a heat moldable thermoplastic material, heating the laminate to the molding temperature of said thermoplastic material, inserting a forming core inside said holster and applying pressure from the outside of said holster while said temperature is reduced to a level below the molding temperature.

Abstract: A double-walled paper container produced by placing a preformed paper container in a shaping die set cavity of a vacuum draw shaping apparatus, positioning a single piece of synthetic resin film or sheet on the top of said paper container, holding the film at the peripheral edge thereof, heating the film to make the plastic film, stretching the film and applying negative pressure to the film to line said preformed paper container with the film is in water-tight fashion and wherein the lined paper container has a good shape holding ability and is hygienic for the user thereof.

Abstract: In a process for producing a fused fabric a fluid is passed in contact with the surface of a fabric on the surface opposite that exposed to sufficient infrared radiation to fuse at least a portion of the synthetic thermoplastic fibers which comprise at least a portion of the fabric.

Abstract: A method for manufacturing thin-walled articles from crystalline thermoplastic material comprising the steps of extruding a continuous web of hot crystalline thermoplastic material at an extrusion temperature above the crystalline melting temperature range of the material, substantially immediately rapidly precooling the opposite surfaces of the web to form therealong thin supportive layers having a temperature in the range wherein the said material is not further plastically deformable and wherein further growth of crystals is essentially avoided, while the hotter core material between said layers is cooled to a temperature adjacent to but above the crystalline melting temperature range and is held in a substantially crystal free condition, transporting the so precooled web into a thermoforming station within a sufficiently short time period to essentially maintain over the web thickness the above mentioned temperature profile produced by precooling, and then thermally forming at a rapid cooling rate said we

Abstract: A method of manufacturing thin-walled articles by thermoforming from crystalline thermoplastic sheet or web material wherein the sheet or web is rapidly precooled from extrusion temperature, and the outer surface layers reheated prior to thermoforming.

Abstract: Plastics foil is shaped in a deep drawing apparatus by being placed in a mould, while the foil is below its deformation temperature, having heated wall surfaces and by applying a pressure differential to the foil so that it progressively stretches and contacts the mould wall. The progressive heating and stretching of the foil ensures that the corners of the moulded article are not thinner than the remaining portions of the moulded article, thus reducing the amount of plastics material necessary for an article of given strength.

Abstract: A method of and apparatus for uniformly debossing and perforating a ribbon of thermoplastic sheet material or film through the use of vacuum in combination with a flash heating source such as a flow of hot air. The apparatus causes a ribbon of such film to be forwarded from a supply such as a roll of thermoplastic material, thence about a circumferentially extending portion of a rotating debossing-perforating cylinder, and then downstream where the debossed and perforated film may be further processed or where it may be wound on a spool to form a roll thereof. The debossing-perforating cylinder comprises a perforated tubular member through which a plurality of independently adjustable levels of vacuum can be applied from within the cylinder to circumferentially spaced sections of the film in contact with the exterior surface of the perforated tubular member. The apparatus further causes a virtual curtain of hot air to be directed radially inwardly towards a predetermined zone of the perforated tubular member.

Abstract: A method of forming articles from thermoplastics sheet by free-blowing, without use of moulds, in which the sheet is pre-heated to elastic state, free-blown by establishing a differential fluid pressure between opposite faces of the sheet and maintained at optimum temperature during the period of free-blowing by heating or cooling by heat-exchange between the sheet and fluid flowing over at least one face. Apparatus for performing the method comprises a tank diversible into two halves adapted to hold the sheet edgewise in between, the differential fluid pressures being established between the volumes in the two halves and fluid flow over the face of the sheet being established in one half.

Abstract: Thermoplastic parts are formed by a process that produces at least one surface that is a direct replication of the mold surface without secondary operations, e.g., a "Class A" surface. The process is particularly suitable for the production of large parts such as automobile panels, refrigerator panels and the like especially those employing a high-viscosity resin and particularly those parts made by blow-molding. The process comprises pressing at a selected pressure a plastic preform heated above the glass transition temperature (Tg) against a suitably smooth or detailed mold surface held at a temperature below the Tg of the resin; raising, preferably rapidly, the mold to a temperature above Tg for the time necessary to raise above Tg a depth of resin sufficient to remove surface imperfections, die lines, and pores, and fill voids, and substantially embed included matter; and rapidly cooling the mold until the molded part is below Tg when pressure may be released and the mold opened.