Plastic and nonmetallic article shaping or treating: processes – Pore forming in situ – Composite article making
Patent
1997-09-12
1998-11-24
Kuhns, Allan R.
Plastic and nonmetallic article shaping or treating: processes
Pore forming in situ
Composite article making
264132, 264134, 264161, 264309, 264321, B29C 4406
Patent
active
058402241
ABSTRACT:
A method and apparatus (32) for making a three-dimensionally formed laminate (20) by positioning a mask (62) having an opening (64) above a flexible film (52) for rotation therewith such that a foamable liquid mixture (71) sprayed downwardly through the mask opening onto the film is distribute with the predetermined shape of the laminate to be formed. Separation of the mask (62) and the film (52) with the foamable liquid mixture (71) remaining on the film for processing during a transient state after substantial completion of expansion but before substantial curing. A flexible sheet (26) and the film (52) with the foam (71) therebetween are positioned between first and second three-dimensionally contoured mold surfaces (84,86) that are moved toward each other while the foam is in its transitory state to form the flexible sheet and provide a collapsed foam layer (28) that is bonded to the flexible sheet with the predetermined shape as the three-dimensionally formed laminate (20). A first frame (50) supports the film (52) on which the foam is distributed by the rotation on a rotatable table (44), while a second frame provided by a hoop assembly (72) supports the flexible sheet (26). A hooping station (36), a cutting station (40) for trimming foam flash, and a backing station (42) for providing a backing layer are also provided. A second mask (122) is also used to register the collapsed foam layer (28) and the mold surfaces (84,86).
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Kuhns Allan R.
Namba Corporation
LandOfFree
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