Method of producing a deep-drawn formed plastic piece

• US 5,108,530 A
• Filed: 12/01/1989
• Issued: 04/28/1992
• Est. Priority Date: 12/01/1988
• Status: Expired due to Term

• Current Assignee: Bayer Healthcare LLC (Bayer AG)
• Original Assignee: Bayer AG
• Inventors: Niebling, Curt Jr., Wank, Joachim
• Primary Examiner(s): Weston, Caleb
• Application Number:
  US07/444,200
• Time in Patent Office: 879 Days
• Field of Search: 156/245, 156/285, 264/500, 264/510, 264/544
• US Class Current: 156/245
• CPC Class Codes: B29C 45/1418 the inserts being deformed or preformed, e.g. by the injection pressure
• CPC Class Codes: B29C 51/10 Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 51/14 using multilayered preforms or sheets
• CPC Class Codes: B29C 67/0029 Cold deforming of thermoplastics material B29C43/16, B29C59/00 take precedence
• CPC Class Codes: B29C 70/78 Moulding material on one side only of the preformed part
• CPC Class Codes: B29L 2031/3008 Instrument panels
• CPC Class Codes: B29L 2031/722 Decorative or ornamental articles
• CPC Class Codes: B29L 2031/747 Lightning equipment
• CPC Class Codes: B60K 37/00 Dashboards as road-vehicle superstructure sub-units B62D25/14
• CPC Class Codes: F21W 2111/00 Use or application of lighting devices or systems for signalling, marking or indicating, not provided for in codes F21W2102/00 – F21W2107/00

Abstract

A method of manufacturing a deep-drawn formed plastic piece comprises providing a cold-stretchable sheet material with a coating selected from a group of an ink film, an ink imprint, a vacuum evaporated metallic thin film, and an electrically conductive varnish film. The coated sheet is heated with a fluid pressure medium which has a fluid medium pressure of more than 20 bars, and at an operating temperature lower than the softening temperature of the sheet material, in order to deform the sheet material isostatically to obtain the deep-drawn formed coated plastic piece.

Claims

1. A method of manufacturing a deep-drawn formed plastic piece comprising the steps of:

providing a cold-stretchable sheet material with a coating selected from the group of an ink film, an ink imprint, a vacuum evaporated metallic thin film, and an electrically conductive varnish film; and

treating said coated sheet with a fluid pressure medium having a fluid medium pressure of more than 20 bars, and at an operating temperature lower than the softening temperature of the sheet material, to deform the sheet material isostatically in order to obtain the deep-drawn formed coated plastic piece.

2. A method according to claim 1, wherein treating of the sheet material is conducted during a period of time of less than 5 seconds.

3. A method according to claim 1, wherein treating of the sheet material is conducted abruptly.

4. A method according to claim 1, wherein a dual-layer sheet material is formed in a single step, and wherein the coating is provided on an inner surface of the dual-layer sheet material.

5. A method according to claim 1, wherein the cold-stretchable sheet material has a thickness of between 40 and 2000 μ

m.

6. A method according to claim 1, wherein a cold-stretchable sheet material comprising plastic materials based on polycarbonates, polyamides, polyimides, polyesters, organic cellulose esters, polyarylates or polyfluorohydrocarbons is formed.

7. A method according to claim 1, wherein treating takes place against a resiliently supported wall portion of a mold cavity.

8. A method according to claim 1, wherein a thin-walled deep-drawn piece is obtained after forming and that piece is subsequently injection-reinforced with a plastic composition.

9. A method according to claim 1, wherein the operating temperature is above the glass transition temperature of the coated sheet material.

10. A method according to claim 9, wherein the operating temperature is above the softening temperature of the coating material.

11. A method according to claim 10, wherein treating of the sheet material is conducted abruptly.

12. A method according to claim 1, wherein the operating temperature is between 80°

and 130°

C.

13. A method according to claim 12, wherein the fluid medium pressure is between 50 and 300 bars.

14. A method according to claim 13, wherein the cold-stretchable sheet material has a thickness of between 40 and 2000 μ

m.

15. A method according to claim 13, wherein treating takes place against a resiliently supported wall portion of a mold cavity.

16. A method of manufacturing a deep-drawn formed plastic piece, comprising:

providing a cold-stretchable substantially flat sheet material with a coating, with at least a portion of said coating forming a graphic representation; and

applying a fluid pressure medium to said coated cold-stretchable sheet material at an operating temperature below the softening temperature of the sheet material and at a fluid medium pressure of more than 20 bars whereby deforming the sheet material isostatically in order to obtain said deep-drawn formed plastic piece without any significant distortion to said graphic representation.

17. A method according to claim 16, wherein the fluid medium pressure is between 60 and 250 bars.

18. A method according to claim 16, wherein treating of the sheet material is conducted during a period of less than 2 seconds.

19. A method according to claim 16, wherein treating takes place against a resiliently supported wall portion of a mold cavity.

20. A method according to claim 16, wherein coating is selected from one of the following group of coatings, an ink film, an ink imprint, a vacuum evaporated metallic thin film and an electrically conductive varnish film.