Methods and apparatus for forming molded thermal plastic polymer components
First Claim
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1. A method of forming a multi-dimensional reinforced composite structure, the method comprising:
- positioning a first layer of one or more sheets of flexible reinforced thermoplastic against a first mold;
positioning a first layer of a porous material against the first layer of sheets of reinforced thermoplastic;
positioning an inflatable bladder against the first layer of porous material;
positioning a second layer of porous material against the inflatable bladder;
positioning a second layer of one or more sheets of flexible reinforced thermoplastic against the second layer of porous material and on an opposite side thereof from the inflatable bladder;
forming a common mold cavity using the first mold and a second mold with the first and second layers of flexible reinforced thermoplastic, the first and second layers of porous material, and the inflatable bladder therebetween;
applying forming forces of heat, pressure and vacuum to the first layer of sheets and the second layer of sheets to urge the first layer of sheets of reinforced thermoplastic against the first mold, the first layer of porous material against the first layer of sheets with uniform pressure, the second layer of sheets of reinforced thermoplastic against the second mold, and the second layer of porous material away from the first layer of porous material and against the second layer of sheets with uniform pressure to form the reinforced composite structure having a hollow interior with the first and second layers of porous material facing each other, the forming forces causing the first layer of sheets to form to the shape of the first mold and mechanically bond with the first layer of porous material by partially melting into the first layer of porous material and the second layer of sheets to form the shape of the second mold and mechanically bond with the second layer of porous material by partially melting into the second layer of porous material.
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Abstract
Apparatus and methods of forming a molded thermoplastic piece are provided. The molded thermoplastic piece can have an outer layer of one or more sheets of reinforced flexible thermoplastic and a porous layer, such as cork. The outer layer can a mechanical bond with the porous layer.
64 Citations
17 Claims
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1. A method of forming a multi-dimensional reinforced composite structure, the method comprising:
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positioning a first layer of one or more sheets of flexible reinforced thermoplastic against a first mold; positioning a first layer of a porous material against the first layer of sheets of reinforced thermoplastic; positioning an inflatable bladder against the first layer of porous material; positioning a second layer of porous material against the inflatable bladder; positioning a second layer of one or more sheets of flexible reinforced thermoplastic against the second layer of porous material and on an opposite side thereof from the inflatable bladder; forming a common mold cavity using the first mold and a second mold with the first and second layers of flexible reinforced thermoplastic, the first and second layers of porous material, and the inflatable bladder therebetween; applying forming forces of heat, pressure and vacuum to the first layer of sheets and the second layer of sheets to urge the first layer of sheets of reinforced thermoplastic against the first mold, the first layer of porous material against the first layer of sheets with uniform pressure, the second layer of sheets of reinforced thermoplastic against the second mold, and the second layer of porous material away from the first layer of porous material and against the second layer of sheets with uniform pressure to form the reinforced composite structure having a hollow interior with the first and second layers of porous material facing each other, the forming forces causing the first layer of sheets to form to the shape of the first mold and mechanically bond with the first layer of porous material by partially melting into the first layer of porous material and the second layer of sheets to form the shape of the second mold and mechanically bond with the second layer of porous material by partially melting into the second layer of porous material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 16, 17)
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11. A method of forming a filled, multi-dimensional reinforced composite sandwich structure, the method comprising:
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positioning a first layer of one or more sheets of flexible reinforced thermoplastic against a first mold side; positioning a first foam bonding layer against the first layer of sheets of reinforced thermoplastic; positioning a second foam bonding layer over the first foam bonding layer; positioning a second layer of one or more sheets of flexible reinforced thermoplastic against the second foam bonding layer; moving one or both of the first mold side and a second mold side together to form a mold cavity with the first and second layers of flexible reinforced thermoplastic and first and second foam bonding layers therebetween; applying forming forces of at least one of heat, pressure and vacuum to the first and second layers of flexible reinforced thermoplastic and the first and second foam bonding layers to urge the first layer of reinforced thermoplastic and the first foam bonding layer toward the first mold side and the second layer of reinforced thermoplastic and the second foam bonding layer toward the second mold side, the forming forces causing the first layer of flexible reinforced thermoplastic to form to the shape of the first mold side and mechanically bond with the first foam bonding layer and the second layer of flexible reinforced thermoplastic to form the shape of the second mold side and mechanically bond with the second foam bonding layer and having a hollow interior with the first and second layers of foam bonding material facing each other; joining peripheral edges of the first and second layers of flexible reinforced thermoplastic to form a hollow composite structure; and filling the hollow composite structure with a foam, the foam forming a mechanical bond with the first and second foam bonding layers. - View Dependent Claims (12, 13, 14, 15)
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Specification