USRE45964EActiveUtility

Method for producing hollow bodies from plastic and hollow plastic bodies with novel properties

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Assignee: CARCOUSTICS TECHCONSULT GMBHPriority: Oct 16, 2009Filed: Sep 16, 2015Granted: Apr 5, 2016
Est. expiryOct 16, 2029(~3.3 yrs left)· nominal 20-yr term from priority
Inventors:Markus LugerRichard L. Geissler
B32B 1/08B60R 13/08B29C 43/203E04B 2001/8461B29K 2995/0015B32B 27/30B60R 13/0838B29K 2995/0002B29K 2105/04B32B 25/08B29C 2043/3613B32B 27/08B32B 27/40B29C 2043/566E04B 2001/8476B32B 27/32E04B 1/86B32B 1/02B32B 5/18E04B 2001/8414B32B 25/00B29C 43/021Y10T428/1376B32B 1/00
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PatentIndex Score
0
Cited by
16
References
31
Claims

Abstract

A hollow plastic body comprises a material composite consisting of a stamp-formed panel or sheet-like first layer of a first thermoplastic synthetic material, an optionally stamp-formed panel or sheet-like second layer of a second synthetic material, and an open-cell or mixed-cell foam layer of a third synthetic material disposed between the first and the second layer. The foam layer may be compressed at least in some sections in accordance with the stamped form of the first layer and/or the second layer. The foam layer may be in mechanical contact with the first or/and second layer substantially only in the compressed sections. Advantageous manufacturing methods for hollow plastic bodies are further disclosed.

Claims

exact text as granted — not AI-modified
What is claimed is: 
     
       1. A method for producing hollow plastic bodies by means of a heated molding tool, which forms a cavity, comprising the steps of:
 a. providing a material composite consisting of:
 i. a first panel or sheet layer of a first thermoplastic synthetic material, 
 ii. a second panel or sheet layer of a second synthetic material, and 
 iii. a panel-like, open-cell or mixed-cell foam layer of a third synthetic material disposed between the first and the second layer; 
 
 b. feeding the material composite to the opened cavity of a heated molding tool; and 
 c. closing the molding tool, wherein pressure is applied onto the material composite at least in some sections such that, in the pressurized sections, at least one of the first layer and the second layer is thermoformed and the foam layer is compressed, which results in a permanent deformation of at least one of the first layer and the second layer, and of the foam layer; 
 and further comprising a process control in which at least one of the first layer and the second layer, in the molding tool, detaches partially from the foam layer in such a way that the foam layer is in mechanical contact with at least one of the first layer and the second layer substantially only in the compressed sections. 
 
     
     
       2. The method of  claim 1 , wherein air is drawn out of the cavity when the molding tool is being closed. 
     
     
       3. The method of  claim 2 , wherein a negative pressure is generated in the cavity when air is being drawn out. 
     
     
       4. The method of  claim 1 , wherein air or an inert filling gas is blown between the foam layer and at least one of the first layer and the second layer when the material composite is being fed to the cavity of the molding tool. 
     
     
       5. The method of  claim 1 , wherein the first layer is thermally welded, in the pressurized sections, to at least one of the second layer and the foam layer. 
     
     
       6. The method of  claim 5 , wherein said welding connects the first layer to at least one of the second layer and the foam layer at least in some areas at the edges. 
     
     
       7. The method of  claim 5 , wherein the first layer is thermally welded to at least one of the foam layer and the second layer in such a way that the hollow plastic body produced encloses a substantially completely sealed inner space. 
     
     
       8. The method of  claim 5 , wherein the first synthetic material and the second synthetic material can be are thermally welded to each other. 
     
     
       9. The method of  claim 5 , wherein the third synthetic material can be is thermally welded to at least one of the first synthetic material and the second synthetic material. 
     
     
       10. The method of  claim 1 , wherein at least one of the second synthetic material and the third synthetic material is selected from one of a thermoplastic, a duroplastic and an elastomer. 
     
     
       11. The method of  claim 1 , wherein at least one of the first synthetic material and the second synthetic material is selected from the group consisting of ABS, PMMA, PVC, PE, PET, PS, PP, PSEVOHPE, PPEVOHPE, and PEEK. 
     
     
       12. The method of  claim 1 , wherein the third synthetic material is selected from the group consisting of PUR, PPE, PSE, PVCE, NBR, and PF. 
     
     
       13. The method of  claim 1 , wherein the first synthetic material and the second synthetic material are chemically or physically different. 
     
     
       14. The method of  claim 13 , wherein the first synthetic material and the second synthetic material have different colors. 
     
     
       15. The method of  claim 1 , wherein the first layer has different mechanical properties from the second layer. 
     
     
       16. The method of  claim 1 , wherein the first layer has a different material thickness from the second layer. 
     
     
       17. A method for producing a hollow plastic bodies by means of a heated molding tool, which forms a cavity body, comprising the steps of:
 a. providing a material composite consisting of:
 i. a first panel or sheet layer of a first thermoplastic synthetic material,   ii. a second panel or layer of a second synthetic material, and   iii. a panel-like, open-cell or mixed-cell foam layer of a third synthetic material disposed between the first and the second layer;   
 b. feeding the a material composite to the opened a cavity of a heated molding tool, the material composite comprising:
 a first layer of a first synthetic material; and 
 a second layer of a second synthetic material; 
 
 blowing air or an inert filling gas between the first layer and the second layer while feeding the material composite to the cavity of the molding tool; and 
 c. closing the molding tool, whereinapplying pressure is applied onto the material composite at least in some in a plurality of pressurized sections such that, in each of the pressurized sections, at least one of the first layer and the second layer is thermoformed and the foam layer is compressed, which results so as to result in a permanent deformation of at least one of the first layer and the second layer, and of the foam layer; 
 wherein air or an inert filling gas is blown between the foam layer and at least one of the first layer and the second layer when the material composite is being fed to the cavity of the molding tool. 
 
     
     
       18. The method of  claim 17 , wherein further comprising:
 drawing air is drawn out of the cavity when while closing the molding tool is being closed. 
 
     
     
       19. The method of  claim 18 , wherein drawing air out of the cavity comprises generating a negative pressure is generated in the cavity when air is being drawn out. 
     
     
       20. The method of claim 17, wherein applying pressure onto the material composite comprises thermally welding the first layer, in each of the plurality of pressurized sections, to the second layer.  
     
     
       21. The method of claim 20, wherein said thermally welding connects the first layer to the second layer at least in some areas at edges of the plurality of pressurized sections.  
     
     
       22. The method of claim 20, wherein said thermally welding attaches the first layer to the second layer in such a way that the hollow plastic body forms a substantially completely sealed inner space.  
     
     
       23. The method of claim 17, wherein the second synthetic material is one of a thermoplastic, a duroplastic or an elastomer.  
     
     
       24. The method of claim 17, wherein at least one of the first synthetic material or the second synthetic material is selected from the group consisting of ABS, PMMA, PVC, PE, PET, PS, PP, PSEVOHPE, PPEVOHPE and PEEK.  
     
     
       25. The method of claim 17, wherein the first synthetic material and the second synthetic material are chemically or physically different.  
     
     
       26. The method of claim 1, wherein the first layer has different mechanical properties from the second layer.  
     
     
       27. The method of claim 17, wherein the first layer has a different material thickness from the second layer.  
     
     
       28. The method of claim 17, wherein the material composite includes a panel-like, open-cell or mixed-cell foam layer of a third synthetic material disposed between the first layer and the second layer.  
     
     
       29. The method of claim 28, wherein applying the pressure compresses the foam layer in each of the plurality of pressurized sections.  
     
     
       30. The method of claim 29, wherein the foam layer is in mechanical contact with at least one of the first layer or the second layer substantially only in the plurality of pressurized sections.  
     
     
       31. The method of claim 28, wherein the third synthetic material is selected from the group consisting of PUR, PPE, PSE, PVCE, NBR and PF.

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