Method of preparing a molded article

Details Method of preparing a molded article Method of preparing a molded article

2008-03-20

2010-11-30

Lee, Edmund H. (Department: 1791)

Plastic and nonmetallic article shaping or treating: processes

Direct application of fluid pressure differential to...

Starting material is nonhollow planar finite length preform...

C425S388000

Reexamination Certificate

active

07842225

ABSTRACT:
A method of forming a shaped thermoplastic sheet is described. The method includes providing a mold apparatus (1) that includes, a first mold portion (11) having an interior mold surface (14) having a plurality of perforations (26) and a perimeter edge (17). The mold apparatus (11) further includes at least one sheet retainer (35) having an upper surface (38) having a plurality of perforations (41) and a longitudinal axis (44) that is oriented along at least a portion of the perimeter edge (17) of the first mold portion (11). Each sheet retainer (35) is reversibly and controllably: (i) positionable along an x-, y- and/or z-axis relative to the perimeter edge (17); and (ii) rotatable around its longitudinal axis (44), toward and/or away from the perimeter edge (17). A heated thermoplastic sheet (95) is formed and contacted (while at a thermoformable temperature) with the interior surface (14) of the first mold portion (11) and the exterior surfaces (38) of the tubular sheet retainers (35). Reduced pressure is drawn through the perforations (41) of the sheet retainers (35) thereby retaining a portion of the heated thermoplastic sheet (95) thereon. The sheet retainers (35) are moved along the x-, y- and/or z-axes, and optionally rotated, with the sheet retained thereon, relative to the perimeter edge (17). The heated thermoplastic sheet (95) is allowed to cool, and a shaped thermoplastic sheet retaining the contour of interior mold surface (14) is formed.

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