Method for making self-supporting thermoplastic structures

Plastic and nonmetallic article shaping or treating: processes – Direct application of electrical or wave energy to work – Forming articles by uniting randomly associated particles

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Details

264483, 264517, 264121, 264309, 264DIG72, B29C 3508, B29C 4108

Patent

active

060868139

ABSTRACT:
A technique for forming self-supporting structures with thermoplastic material incorporates a plasma-heated spray of thermoplastic material with glass fiber reinforcement, such as glass fibers. The material is sprayed into a mold which is shaped to create the desired form and configuration of the self-supporting structure. A mixture of thermoplastic powder and reinforcing fibers is carried by a stream of inert gas through a plasma region. The thermoplastic material is melted as it passes through the plasma region and the resulting plasma is sprayed against the surface of a form mold. The thickness of the resulting structure can be varied from region to region by changing the speed of movement of a spray nozzle relative to the form, using a plurality of spray nozzles that can be selectively activated and deactivated, or by providing a plurality of coats of sprayed thermoplastic material, one after another.

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