Twin sheet thermformed structure and method of making same
First Claim
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1. A method of producing a load-bearing twin sheet thermoformed structure comprising:
- providing a mold surface having a major rib producing surface comprising at least two tabs separated by a gap;
thermoforming a first thermoformable sheet over said major rib producing surface so as to produce a rib having first side wall, second side wall and rib floor in said first sheet of thermoformable material;
fusing said first side wall to said second side wall by vacuum forming said first side wall and said second side wall into contact within said gap;
fusing said first thermoformable sheet to a second sheet of thermoformable material; and
,withdrawing said mold surface from said first sheet.
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Abstract
In producing a twin sheet thermoformed structure, a mold is provided with major rib producing structures segregrated into discrete tabs with gaps between tabs. A first sheet of material is fused upon itself by drawing the material into the gaps between tabs from both sides of the gap. The material drawn into the gaps fuses upon contact with material being drawn into the gap from the other side forming a cross rib which tends to stabilize the side walls of the major rib. The first sheet is then fused to a second sheet of material to create a twin sheet structure.
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5 Claims
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1. A method of producing a load-bearing twin sheet thermoformed structure comprising:
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providing a mold surface having a major rib producing surface comprising at least two tabs separated by a gap; thermoforming a first thermoformable sheet over said major rib producing surface so as to produce a rib having first side wall, second side wall and rib floor in said first sheet of thermoformable material; fusing said first side wall to said second side wall by vacuum forming said first side wall and said second side wall into contact within said gap; fusing said first thermoformable sheet to a second sheet of thermoformable material; and
,withdrawing said mold surface from said first sheet. - View Dependent Claims (2, 3, 4, 5)
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Specification