Method of molding load-bearing articles from compressible cores and heat malleable coverings
First Claim
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1. A method of forming articles including a shape defining compressible core member, and a thermoplastic external shell, said method comprising the steps of:
- providing a shape defining compressible core member including a first surface and a second surface, wherein at least one surface includes a pattern of features, said core member being comprised of expanded polymer;
positioning said core member adjacent to a first heated pliable thermoplastic sheet that is without a preformed contour, to form a stack including said first sheet and said core member, wherein said first pliable thermoplastic sheet is longer and wider than said core member;
compressing said stack between a first molding tool and a second molding tool, wherein said first molding tool has a surface at least as long and as wide as said core member, and said second molding tool has a surface at least as long and as wide as said core member and a contour complimentary to the features of said at least one surface of said core member, wherein said core member is used as a plug assist to move said sheet into the contour of said second molding tool when compressing said stack;
holding said stack between said first and said second molding tools until said stack cools and bonds form between portions of said core member and said sheet in contact with one another;
removing said stack from said first and second molding tools, wherein the volume of said core member is greater before said core member is compressed between said first and said second molding tools than the volume of said core member after said stack is removed from said first and second molding tools andwherein said core member has an uncompressed volume that is greater than a volume of a space formed by closure of said first and second molding tools.
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Abstract
Load-bearing articles are manufactured from shape defining compressible cores and thermoplastic shells. The manufacture of these articles requires specific methods and tools. Articles that can be manufactured using these methods include relatively lightweight pallets with high load-bearing capacity.
73 Citations
25 Claims
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1. A method of forming articles including a shape defining compressible core member, and a thermoplastic external shell, said method comprising the steps of:
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providing a shape defining compressible core member including a first surface and a second surface, wherein at least one surface includes a pattern of features, said core member being comprised of expanded polymer; positioning said core member adjacent to a first heated pliable thermoplastic sheet that is without a preformed contour, to form a stack including said first sheet and said core member, wherein said first pliable thermoplastic sheet is longer and wider than said core member; compressing said stack between a first molding tool and a second molding tool, wherein said first molding tool has a surface at least as long and as wide as said core member, and said second molding tool has a surface at least as long and as wide as said core member and a contour complimentary to the features of said at least one surface of said core member, wherein said core member is used as a plug assist to move said sheet into the contour of said second molding tool when compressing said stack; holding said stack between said first and said second molding tools until said stack cools and bonds form between portions of said core member and said sheet in contact with one another; removing said stack from said first and second molding tools, wherein the volume of said core member is greater before said core member is compressed between said first and said second molding tools than the volume of said core member after said stack is removed from said first and second molding tools and wherein said core member has an uncompressed volume that is greater than a volume of a space formed by closure of said first and second molding tools. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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23. A method of forming articles comprising the steps of:
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providing a compressible core member that includes a first surface and a second surface, wherein said second surface of said core member includes a contour; providing a heated thermoplastic sheet adjacent said core member, said sheet being without a preformed contour; positioning said core member and said sheet between first and second molding tools; wherein said second molding tool has a contour that is complementary to the contour of said core member and said core member has an uncompressed volume that is greater than a volume of a space formed by closure of said first and second molding tools; compressing said core member and said sheet together between said first and second molding tools, wherein said core member is used as a plug assist to move said sheet into the contour of said second molding tool and wherein the core member is compressed to a compressed volume that is received by the volume of the space formed by closure of said first and second molding tools; holding said core member and said sheet between said first and said second molding tools until said core member and said sheet cool and bonds form therebetween; and removing said sheet and said core member from said first and second molding tools, wherein the volume of said core member is greater before said core member is compressed between said first and said second molding tools than the volume of said core member after said core member and said sheet are removed from said first and second molding tools. - View Dependent Claims (24, 25)
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Specification