Abstract: A method for cutting openings in a sheet of thermoformed containers. The sheet of containers is indexed into a cutting assembly. The cutting assembly includes a shear plate having a plurality of openings formed therethrough, and having an upper surface which defines a cutting plane. A locating means including a plurality of anvils is raised so that the anvils enter the containers and raise the sheet toward the shear plate. The end portions of the containers are located within the openings of the shear plate, and a portion of the containers is positioned in the cutting plane. The cutting assembly includes a blade mounted on piston/cylinder assembly for sliding movement along the upper surface of the shear plate. The cylinder is actuated to move the blade along the cutting plane. The blade cuts off the portion of the containers and creates an opening in the containers.

Abstract: A method and apparatus for forming a skid-resistant surface on a thermoformed object such as a bed liner. The method includes forming a blank of extruded plastic material, abrading the surface with a wire brush, reheating the blank and thermoforming the blank to open the abraded surface of the blank. The apparatus includes an extruder delivery mechanism delivering a blank of sheet material to a wire brush which is turned by an electric motor at a speed slightly greater and in the same direction as the travel of the blank under the roller.

Abstract: The two ends of an article to be processed which is in the form of a sheet are held by means of a fixed clamp and a movable clamp, the article being held by applying bias by means of a biasing cylinder to the movable clamp in a direction such as would separate it from the fixed clamp and hole-forming processing being performed by means of a laser beam. Since the sheet-like article is held under tension, flatness of even a thin sheet can be maintained and since the underneath space is open, there is no reflection of laser light after passing through the holes that are formed and any processing waste can easily be removed.

Abstract: A process for producing deformable acrylic panels with increased resistance to abrasion and scratching preferably for sanitary articles to be produced by the deep-drawing process. Immediately prior to the deep-drawing step, a type of lacquer is applied to an acrylic panel. The lacquer contains dispersed nanoscale particles preferable of an inorganic material. The semifinished acrylic panel is heated and subsequently deep-drawn. The lacquer coating is applied to the semifinished acrylic panel with the help of rollers or a doctor blade. In addition, the lacquer coating can be applied by immersing or flooding the semifinished acrylic panel.

Abstract: A method of thermoforming a thin flexible film comprising a series of steps. A thin flexible film capable of being thermoformed is heated until it is pliable. A mold having first and second surfaces on different planes forms a thermoformed article having a contoured surface. A first portion of the pliable film is contacted with the first surface. A first vacuum is applied through the first surface to draw the first portion against the first surface. After the first portion of the film is drawn against the first surface, a second portion of the film contacts the second surface. A second vacuum is applied through the second surface to draw the second portion of the film against the second surface. Air trapped between the mold and the film is first removed between the first surface and the first portion of the film and then removed from between the second surface and the second portion of said film so that the thermoformed article is substantially defect-free.

Abstract: A method of forming a golf ball by forming a core center, forming a laminate of core material, forming the laminate around the core center to form a core and forming a cover around the core. The laminate preferably consists of at least three layers of different polybutadiene rubbers.

Abstract: In manufacturing a resin bag, a first resin sheet is disposed in a cavity of a mold, and a heat-resisting sheet smaller than the first resin sheet is overlaid on the first resin sheet to expose a periphery of the first resin sheet along the outer periphery of the heat-resisting sheet. Then, a molten resin is injected into the cavity in a state where the mold is opened, and the mold is closed while pressing and expanding the injected resin in a molten state. Thus, the injected resin covers the heat-resisting sheet and the exposed periphery of the first resin sheet. The second resin sheet is molded, and the periphery of the second resin sheet is bonded with the periphery of the first resin sheet at the same time.

Abstract: A single component, extremely low viscosity, pre-catalyzed high functionality diepoxide and epoxy resin system has been developed. This resin system has good thermal stability, an extended work life and is capable of being refrigerated to -18 C. and stored for extended periods of time with little or no change in physical or mechanical properties. The resin system has direct applications in a number of industries including, but not limited to, the aircraft and spacecraft industries. The resin system is a mixture of specific epoxy resins and curing agents that when combined form an extremely low viscosity resinous system that may be readily cured at a temperature as low as 52 degrees C. into novel thermoset materials prepared therefrom, which are characterized by superior strength properties and methods for preparing the same.

Abstract: A thermoforming machine utilizes two clamping frames to advance cut sheets through heating and forming stations, with the clamping frames returned via an overhead path above the oven in the heating station. Pneumatic cylinders arranged about the inner perimeter of the frames are operated to grip the sheet and release the sheets, which are pressurized and released via fluid connections established when the frames are lifted from a transfer bar structure at the loading and forming stations. The clamping frames have pivoted end sections which are engaged by extendible gear posts at the forming station to bend the clamped sheet into greater conformity with the tooling shape prior to forming.

Abstract: A method and an apparatus for applying a cover sheet of plastic material to the surface of a mold, during the molding of panels and/or of plastic pieces. The cover sheet is pneumatically held and stretched by a support frame provided with a sheet clamping groove, which peripherally extends for at least part or the edges of the mold; the support frame is provided with an air suction chamber connected to the sheet clamping groove by at least an air suction slot which opens on the bottom of the groove. The pneumatic support frame for the cover sheet and the mold are movable between each other for pneumatically adhering the cover sheet to the edges and the internal surface of the mold.

Abstract: A manufacturing process for reverse building complex-shaped vehicle fuel tanks using complementary female mold half sections which, when joined together about their mating peripheral edges, exactly duplicate the fuel cavity framework of the vehicle into which the completed tanks are to be mounted. Whereas previous reverse building processes employed light weight, air-curable, non-tear fabric such as nylon fabric reinforcement to both halves of the female molds, such fabric is applied only to the mold for the top half of the fuel tank of the present invention. Self-sealing, autoclave curable materials are used in the bottom half of the fuel tank, thereby providing improved ballistic protection to the lower portion of the tank.

Abstract: In manufacturing a photo film cassette, a disk producing apparatus includes a web supplier which conveys the web from a web roll to the web conveyor. The web conveyor includes two chains which convey the web in an intermittent fashion, and which include pointed portions which serially penetrate an edge portion of the web. A heater disposed upstream from the web conveyor heats the edges of the web. At the heating/forming unit, a heating plate is lowered toward the web at the same time as the female mold is raised toward the web, and the web is squeezed between them before the heating and vacuum/air pressure forming takes. Clampers/coolers disposed upstream and downstream from the heating plate and female mold squeeze the web in fixed fashion to prevent wrinkles on the web. A web/sheet cutter device includes an upper punch above the web and a lower die under the web, which squeeze the web, and cut the web into a sheet having a plurality of disk-like portions.

Abstract: A foil-decorating injection molding method and a foil-decorating injection molding apparatus adjust the tautness of a decorative sheet fed onto a parting surface of a female mold so that tensions T.sub.1, T.sub.2 and T.sub.3 of the decorative sheet during a sheet feed operation of the sheet feed means, at the start of the sheet clamping operation of the clamper for pressing and fixing the decorative sheet and at a moment immediately before the completion of the sheet clamping operation, respectively, meet an inequality: T.sub.1 .gtoreq.T.sub.2 >T.sub.3 to prevent the decorative sheet from breaking or slipping off the clamper when clamping the decorative sheet on the parting surface of the female mold.

Abstract: A method to produce a dust control mat with stronger longitudinal borders by co-calendering the rubber backing thereof with narrow strips of carboxylated nitrile rubber prior to formation of the dust control into a unitary product for use as a dust control mop.

Abstract: In the method, after the pattern-bearing film is fed to the female mold, the distal end of the film is fixed under a lower portion of the female mold, and at the same time the film is retreated by a force from the film supply portion. Thus, this tightens up the film so that the slacks or wrinkles cannot be formed on the film. Therefore, the film can be fortunately spread around the parting surface of the female mold. In the apparatus, the film suppressing frame is pressed to the female mold through the sliding rod arranged in the female mold, in such a manner that the female mold embraces the frame. Thus, the pressing of the frame is performed by a simple structure, and the film is accurately positioned to the internal surface of the female mold. Also, the film suppressing frame is constituted to advance from and retreat to the female mold. Thus, this causes a space between the both molds and an outside standby position to be useless. A space around the apparatus can be effectively utilized.

Abstract: A photo film cassette includes a spool core (4), on which the photo film is wound in a form of roll. A cassette shell (2a, 2b) contain the spool core in rotatable fashion. First and second disks (6a, 6b) are respectively provided with bearing holes (5) formed in a middle thereof, and respectively secured to ends of the spool core, for regulating positions of sides of the roll. A ring-like lip (11) is formed integrally with a periphery of the first disk, projected toward the roll, contacted on one edge of an outermost turn of the roll, and prevents the roll from being loosened. In a disk producing method, a sheet (21) of thermoplastic resin is heated and softened. Pressurization and/or suction is applied to the heated sheet to fit the sheet on a mold (23d), so as to form a pattern (19, 31, 58, 60) on the sheet. The pattern includes first and second groups of disk-like portions (19) and positioning portions (31, 58, 60) associated with the disk-like portions.

Abstract: A method for manufacturing food container includes the following steps: the husks of rice, oat, corn, soya bean, wheat or the mixture thereof are used as raw material to make food containers; an eatable adhesive is added in order to bind the husks; the bound husks is rolled into a sheet; after sterilizing the sheet with UV light; the sheet is shaped into a container of a desired shape, such as a bowl or a tray; a water-resistant is coated on the surface of the container.

Abstract: The inventive packaging item is e.g. a tray for packing fresh meat. It has at least on its bottom part (10) grooves (11) which open towards the inside of the packaging item. The openings of these grooves are narrower than the inside part of the grooves. If the groove opening is sufficiently narrow e.g 1mm or less, unwanted liquid oozing out of the packed meat is trapped in these grooves (11) and such separated from the meat and kept out of sight of a potential buyer.

Abstract: The present invention concerns a method for the application of a pattern on a work piece of thermoplastic material, preferably plastic, in which method a material, preferably fabric, carrying a predetermined pattern, is brought into contact against said work piece, that the plastic material is heated to a predetermined temperature, and that said patterned material is allowed to remain in contact with the plastic material for a predetermined time, so that the pattern is completely or partly taken up by the work piece, whereupon said pattern carrying material is removed, a method for the production of an object from the work piece with simultaneous application of the pattern, as well as an object produced according to the method.

Abstract: A composite article is prepared by positioning composite material precursor between a layup tool and a sculpted block of an open-celled foam material. The block has a first face sculpted to define a first face of the composite article. A pressure is applied between the layup tool and the block, and thence to the composite material precursor. Simultaneously with the pressure application, the assembly is heated to compact and cure the composite material. The open-celled foam block acts both as a breather material to allow gas to escape from the compacting composite material and a bleeder material to receive resin that is forced out of the composite material under pressure.

Abstract: A method of forming a socket for connecting a prosthesis to an amputated extremity including forming a molded cast into which an amputated extremity conforms, the molded cast having a closed distal end for positioning adjacent one end of the amputated extremity and an open proximal end for surrounding the amputated extremity, forming a vacuum assembly by connecting an attachment device for receiving a vacuum tube to the distal end of the mold cast and attaching a first end of the vacuum tube to the attachment device. Subsequently, wrapping a formable plastic layer around a portion of the vacuum tube, the attachment device and at least the distal end of the molded socket. The plastic layer is sealed around the vacuum tube and at least the distal end of the molded cast such that trapped air between the plastic layer and the vacuum assembly can be drawn through the vacuum tube, thus conforming the formal plastic layer to at least the distal end of mold cast and the attachment device.

Abstract: Compositions, methods, and systems for manufacturing articles, particularly containers and packaging materials, having a highly inorganically filled matrix. Suitable inorganically filled mixtures are prepared by mixing together an organic polymer binder, water, one or more aggregate materials, fibers, and optional admixtures in the correct proportions in order to form an article which has the desired performance criteria. The inorganically filled mixtures are molded to fashion a portion of the mixture into a form stable shape for the desired article. Once the article has obtained form stability, the article is removed from the mold and allowed to harden to gain strength. The articles may have properties substantially similar to articles presently made from traditional materials like paper, paperboard, polystyrene, plastic, or metal. They have especial utility in the mass production of containers, particularly food and beverage containers.

Abstract: Bathtub or shower stall liner vacuum forming system for the forming of a liner to be positioned over an existing bathtub comprises a bathtub liner vacuum machine, a plumbing apparatus and a lift for moving the plumbing apparatus. The bathtub liner vacuum machine comprises a frame member, a track member, an oven and a skirt forming member. The plumbing apparatus includes a conventional plumbing fixture, a manifold, mesh member and a vacuum pump. Upon positioning of the formable member within the frame member and skirt forming member, the frame member is rolled along the track member into the oven. When the formable member is heated to the desired temperature, the bathtub is positioned into contact with the formable member and the air trapped therebetween is removed with the aid of the vacuum pump. As the air is evacuated, the formable member takes on the configuration of the conventional plumbing apparatus and mesh member. The invention further includes a method for forming a bathtub liner.

Abstract: A precut die apparatus arranged and adapted for use in a thermoform-trimming method and system to produce plastic molded articles, and to the method and system in which the apparatus is employed. The precut apparatus is positioned, in the method and system, between the form press and the trim station. The precut apparatus is arranged to precut, in a desired and selected manner, the thermoformed sheet material containing thermoformed articles therein, about the periphery of the thermoformed articles. The precut provides for a bridged and joining area of the sheet material to allow for slight movement and adjusting of the molded articles for precise alignment in the punch and die trim step of the thermoforming and trimming operation.

Abstract: An apparatus and method for forming thermoplastic containers having a male locking member. The apparatus includes a cavity defining a shape of the container, a stripper movable in a longitudinal direction relative to said cavity, and a retractable lock adjacent to an edge of the cavity. The retractable lock is movable in a transverse direction relative to the cavity between a retracted position and an unretracted position and movable in a longitudinal direction between a first position and a second position. The containers are formed through a process in which the apparatus is sequentially placed in a ready mode, lift mode, disengage mode, and back to the ready mode. In the ready mode, the retractable lock is placed in the unretracted position and first position in order to receive a sheet of plastic material and form a locking member thereon.

Abstract: A densified carbon matrix carbon fiber composite preform is made by vacuum molding an aqueous slurry of carbon fibers and carbonizable organic powder to form a molded part. The molded part is dried in an oven at 50.degree. C. for 14 hours and hot pressed at 2000 psi at 400.degree. C. for 3 hours. The hot pressed part is carbonized at 650.degree. C. under nitrogen for 3 hours and graphitized at 2400.degree. C. to form a graphitic structure in the matrix of the densified carbon matrix carbon fiber composite preform. The densified preform has a density greater than 1.1 g/cc.

Abstract: A method for making a flexible carrier tape for storage and delivery of electronic components by an advancement mechanism is disclosed. The tape includes a strip portion having a top surface, a bottom surface opposite the top surface, and a device for engagingly receiving the advancement mechanism; and a plurality of aligned pockets for carrying the electronic components. The pockets are spaced along the strip portion and opening through the top surface. The device for engagingly receiving the advancement mechanism includes a plurality of hollow protuberances that are spaced equally along the strip portion, open through the strip portion, and extend outwardly from the strip portion. The protuberances are adapted to receive the advancement mechanism within the hollow portion. The method includes simultaneously thermoforming the pockets and the protuberances to provide excellent registration therebetween.

Abstract: A thermoforming process window of a rectangular sheet of a thermoplastic material is determined by calculating its Sag Number during heating. The Sag Number is a function of the sheets length, width and apex depth at the center of sag. Upon the Sag Number being between 10 and 40, preferably 15 and 35, and more preferably 19 and 28, the sheet is ready for forming into an end product.

Abstract: An apparatus and method for producing and bagging decorative grass, such as Easter grass. The apparatus includes an extruder, a godet, a slitter, a cutter, a bagging assembly and a programmable logic controller. The extruder produces a continuous sheet of material, which is fed by the godet into the slitter and cutter. A thickness gauge is provided between the extruder and slitter to measure the thickness of the sheet of material. The slitter has a row of blades which slit the sheet into a continuous length of slitted material. The cutter includes a rotatable blade which transversely cuts the slitted material into a number of individual filaments. The sheet of material is urged through the slitter and cutter by the godet and an air flow produced by a blower. A foaming agent is injected into the extruder to produce low-density decorative grass.

Abstract: A process is disclosed for producing reinforced twin-sheet thermoformed articles comprising the steps of heating first and second sheets of thermoplastic material; forming the sheets in molds; heating a reinforcing insert of thermoplastic material; placing the heated insert on the first sheet in its mold at the location to be reinforced; pressing the second sheet into contact with the heated first sheet and the heated insert to form the insert between the sheets so that a fusion of the thermoplastic sheets and the insert takes place to produce a reinforced section of the article having a desired shape and thickness. Alternative processes are disclosed wherein a heated quantity of thermoplastic liquid material is extruded or injected between the first and second sheets within the first and second molds either by inserting the liquid material before the molds are closed or by injecting it through one of the molds.

Abstract: A self-inflating structure consists essentially of a block of open-cell, resiliently compressible, foam material which has been shaped to a desired form and covered with an airtight envelope having a sealable aperture. The structure can be pressed to expel any air or other fluid out of the foam material and any internal void through the aperture. The structure is kept pressed or the aperture is sealed in order to keep it in its collapsed state. Upon release of the pressing form or the opening of the aperture, the block of foam bounces back to its original state sucking in ambient air and restoring the structure to its full size. The method for shaping the foam block includes extruding, machining, and carving with patterned sets of blades or burning wires.

Abstract: A process is disclosed for producing reinforced twin-sheet thermoformed articles comprising the steps of heating first and second sheets of thermoplastic material; forming the sheets in molds; heating a reinforcing insert of thermoplastic material; placing the heated insert on the first sheet in its mold at the location to be reinforced; pressing tile second sheet into contact with the heated first sheet and the heated insert to form the insert between tile sheets so that a fusion of the thermoplastic sheets and tile insert takes place to produce a reinforced section of the article having a desired shape and thickness. Alternative processes are disclosed wherein a heated quantity of thermoplastic liquid material is extruded or injected between the first and second sheets within the first and second molds either by inserting the liquid material before the molds are closed or by injecting it through one of the molds.

Abstract: An optoelectronic device is fabricated by casting a transparent polymeric body surrounding an electronic component. A reflective layer is formed over the polymeric body. The reflective layer acts as a mirror to reflect light emitted by one electronic component to another electronic component which receives the light. By casting the polymeric body, a consistent and defined shape for optical transmission is provided for forming the shape of the reflective layer.

Abstract: A method and apparatus for forming an article from a sheet of PET material of thickness greater than 1 mm comprises heating the PET sheet to a preforming temperature of approximately 110.degree. C. by heaters, and then forming the sheet onto a heated vacuum mold. The sheet is retained in the mold by the vacuum and the surface of the sheet are maintained at a temperature of approximately 160.degree. C. by the mold and the heater, respectively, until the degree of crystallization of the sheet is in the order of 35%.

Abstract: The invention relates to an apparatus for folding edge sections of molded parts, blanks, or covers provided for them of leather, artificial leather, plastic, or the like, having a sizing plate provided with a cut-out, into which is inserted a pressure plate, the dimensions of the cut-out in the sizing plate corresponding to those of the finished molded part or blank or of a part of it, having a folding plate, on whose side facing the sizing plate, edges are formed for folding over the edge sections of the molded part, blank or cover, and having a base die for accommodating the sizing plate and the pressure plate, the pressure plate inserted into the cut-out of the sizing plate preferably being flexibly supported on the base tool and being vertically movable with respect to the sizing plate and the base die, and the folding plate being retained on a fixing plate, which is vertically movable, for example pneumatically or hydraulically, so as to allow the folding plate to be set down on the sizing plate, as well

Abstract: A method of making microstructure bodies of plastic material. A microstructured plate-like base body which is made by any known molding procedure and which has a first side serving as a first reference plane and a second side which has plastic microstructures projecting therefrom is covered at its second side with a material layer that engages the microstructures, whereupon the material layer is machined to provide a second reference surface parallel to the first reference surface and the base body is then machined parallel to the second reference surface to expose the microstructures projecting therefrom and the material layer is finally removed selectively with respect to the plastic material to release the microstructured bodies.

Abstract: In an operation wherein a metal structure has applied thereto a coating of visco-elastic material is a method of corrosion, sound and vibration-proofing and wherein selected portions or surfaces of the metal structure are protected from having the visco-elastic material applied thereto by placing a masking member on said selected portions or surfaces, the improvement which comprises employing as said masking members thin, thermoplastic foam-walled masking members, such as are manufactured by vacuum forming thermoplastic sheet or by expansion molding of expandable thermoplastic beads.

Abstract: A decorated helmet is formed by applying a decoration to a side of a plastic sheet. The plastic sheet is heated and applied to a helmet shell with the decoration between the plastic sheet and the helmet shell. A vacuum is applied to the heated plastic sheet to stretch the plastic sheet and mold the plastic sheet directly about the helmet shell with the decorations sandwiched between the plastic sheet and the helmet shell.

Abstract: An apparatus with pivoting blades and closable surfaces for forming a sheet of material into a flower pot or flower pot cover having fins. In an embodiment for forming outwardly extending fins, the apparatus includes a male mold and a plurality of plates arranged in pairs to define a forming opening. The male mold has a plurality of fingers which are laterally extendable from the outer periphery of the male mold. A pneumatic or hydraulic piston and cylinder is provided to move the male mold between a storage position spaced from the forming opening and a forming position within the forming opening. Each pair of plates is movable between an open position and a closed position. In operation, the fingers are extended to push folded portions of a sheet of material between the pairs of plates, which are closed to press the folded portions into fins. In an alternate embodiment for forming outwardly extending fins, pairs of movable plates are positioned between stationary segments.

Abstract: In an apparatus and method for resin transfer molding, a mold including at least two cooperating mold sections is placed in a vacuum chamber. A reinforcing material is positioned between the mold sections, which are separated from one another during evacuation of the chamber, thus maintaining the reinforcing material in a substantially uncompressed condition, to ensure that all gasses and/or liquids are evacuated from the reinforcing material and the mold prior to resin injection. After evacuation, the mold sections are brought almost into engagement to substantially define a mold cavity, and resin is injected into the mold cavity. Prior to terminating the resin injection, the mold sections are brought into engagement, and final resin injection is performed. The injected resin is then cured in accordance with the particular type of resin injected.

Abstract: A process of forming a spa shell by selecting a coextruded polypropylene sheet, selectively heating the sheet, vacuum forming the heated sheet on a deep draw female mold to form a molded spa shell shape, flame treating one surface of the molded shell shape, heating the flame-treated surface, and applying a layer of polyurethane foam to the heated surface.

Abstract: A decorative molding for a corner formed by a ceiling and a vertical wall comprises a thin strip of flexible plastic and is secured to the wall by an attachment allowing the molding strip along its upper and lower edges to be flexible to conform with uneven surfaces in the ceiling and/or wall. In one form the strip is attached to the wall by an adhesive. In another form, a wall track and clip arrangement is utilized to provide easy removal from the wall for paint or wallpaper application. A corner element is provided in one form in which ends of the strips are adhesively secured thereto in overlapping engagement. In another embodiment, the strips are telescopically connected to the corner element.

Abstract: A molded cushioning article is made by stuffing a bulky, tape-form nonwoven web such as sliver in a mold cavity and thereafter heat-treating the thus-formed molded form to fusion-bond intersecting points of fibers. Stuffing of the tape-form nonwoven web is effected by laying and superposing it in to-and-fro movements on a molding surface of a mold permeable to air with a space on a backside of the molding surface being kept under reduced pressure. The apparatus used has (a) means for feeding the tape-form nonwoven web into the mold, (b) a mold permeable to air, (c) a mold-supporting frame, (d) suction means for keeping the backside space under reduced pressure, (e) means for successively changing a positional correlation between means (a) and the molding surface, and (f) heat-treating means for fibers to be fusion-bonded.

Abstract: A top sheet and a bottom sheet are thermoformed about a foam core which has feet making spaces for the tines of a fork lift truck. The top and bottom sheets meet at a line on the pallet edge to fuse and bond together and may be applied simultaneously to the core while the core is confined in a mold cavity.

Abstract: An apparatus for thermoforming plastic sheet material which has a frame and complementary mold halves mounted on the frame for movement toward and away from one another. The apparatus has an indexing means which moves along a vertical path to pull the plastic material through the mold and a clamping means disposed between the mold halves which operates with the mold to clamp the plastic sheet around the edges of the forming tool of one mold half. The indexing means and clamping means operate to reduce sag of the plastic material and improve uniformity of the finished article. Operation of the apparatus is enhanced by the use of air pressure, vacuum and cooling during molding and release.

Abstract: A polystyrene foam sheet comprising a polystyrene resin which contains 1 to 15 wt. % of a rubber component having a majority of particle sizes less than about 0.45 microns has been found to be superior for forming deep drawn articles. Optionally one or two films may be extrusion coated or laminated to the foam sheet prior to thermoforming. Also disclosed is a method for thermoforming the foam sheet. Preheat the sheet, clamp the sheet between the matched male and female mold members, move the members into final position while applying a vacuum through both members to both sides of the foamed sheet and then chill formed foam to set a final shape.

Abstract: A polystyrene foam sheet comprising a polystyrene resin which contains 1 to 15 wt % of a rubber component having a majority of particle sizes less than about 0.45 microns has been found to be superior for forming deep drawn articles. Optionally one or two films may be extrusion coated or laminated to the foam sheet prior to thermoforming. Also disclosed is a method for thermoforming the foam sheet. Preheat the sheet, clamp the sheet between the matched male and female mold members, move the members into final position while applying a vacuum through both members to both sides of the foamed sheet and then chill formed foam to set a final shape.

Abstract: Method for forming polyvinyl alcohol (PVA) into surgical elements include forming a mixture of PVA and water into a film by vacuum pressing with a first force, heating, applying a second force two to two hundred times the firs force, drying the film to remove water to a content of less than about 10% by weight based on the weight of the film, and molding the film into a desired shape.

Abstract: A vacuum-formed storage tray for autoclaving medical and dental instruments includes a base panel surrounded by a plurality of integrally joined sidewalls so as to create an interior storage area. The base panel defines a plurality of sterilant apertures. The base panel and sidewalls are created by a vacuum-forming operation which concurrently creates by vacuum forming a plurality of aperture bosses. The vacuum-formed aperture bosses are closed as formed and must be subjected to a post-forming machining operation to cut off the closed end of each aperture boss. Once the closed ends are cut off, the closed aperture bosses become open sterilant apertures. The creation of a plurality of sterilant apertures by a vacuum-forming operation can replace any drilling operations for sterilant holes and economically allows greater variety as to the style and shape of apertures which can be formed in the base panel of the storage tray.

Abstract: The present invention generally relates to a device which can form a lid for a cup. This apparatus is for thermoforming a plastic sheet of material into a plurality of production sheets. Each sheet has a partible port section, which has integrity against passage of fluid, yet which is partible under mechanical pressure so as to open and allow the passage of fluids. The lid structure with a breakaway port is formed by an apparatus including an oven for heating the production piece, mold assembly that has a mold formed as a female cavity with a plurality of grooves formed around the cavity surface and a pressure box assembly that has an open position and a closed position. The breakaway port in the lid structure is formed as a female cavity with accordion-like grooves therearound which expand to engage the outside of the straw. This eliminates escape of the fluid through the breakaway port when the straw is inserted.