Patent ID: 8221668
Filing Date: 2012-07-17
Classification: B29C,B29K,B29L,Y02T,Y10T

Abstract:
1. A process for forming a plastic composite into a predetermined shape from a plastic particulate material and an expandable plastic filler material, each plastic material having a respective melting point, said process comprising the steps of: providing open face complementary open molds made of a material selected from the group consisting of alloys, metals, ceramics, cermets, plastics, and combinations thereof, said open molds being formed into a predetermined shape with at least an open face portion on each of said complementary molds to impart a desired shape; heating at least the face portions of the complementary open molds to an elevated temperature of from about 100° C. to about 865° C. which is above the melting points of the respective plastic particulate material and the plastic filler material; contacting the open face portion of the complementary open molds with the plastic particulate material resulting in two melted plastic skins on the surfaces of the open molds, said contacting occurring while the plastic particulate is at least at room temperature for a dwell time period of from about 1 second to about 30 minutes, said dwell time period being pre-selected to melt the plastic particulate into a molded skin of a plastic article having a skin of a desired thickness of from about 0.001 cm to about 3.0 cm prior to ceasing contact with the plastic particulate, and removing the excess plastic particulate to leave a molded skin of the desired thickness in the open mold; contacting the plastic skin on the face portion of at least one of the open face complementary open molds with the expandable plastic filler material; bringing together the complementary face portions of the heated open molds to adhere the two skins of plastic articles to each other such that an article is formed having a molded surface on both sides.