Patent ID: 8518202
Filing Date: 2013-08-27
Classification: B29C,B29K,B29L,Y10T

Abstract:
1. A method of forming a shaped multilayered article comprising: (a) providing a first mold portion having an interior mold surface, said interior mold surface having a contour; (b) providing a first plastic sheet having a first surface and a second surface defined by a thermoplastic layer having a melting temperature, said first plastic sheet being provided at a temperature that is less than said melting temperature of said thermoplastic layer defining said second surface of said first plastic sheet; (c) forming, from at least one thermoplastic composition, a heated thermoplastic sheet having a temperature that allows said heated thermoplastic sheet to be thermoformable, said heated thermoplastic sheet having a first surface and a second surface, said temperature of said heated thermoplastic sheet being equal to or greater than the melting temperature of said thermoplastic layer defining said second surface of said first plastic sheet; (d) positioning a portion of said second surface of said first plastic sheet in opposition with a portion of said first surface of said heated thermoplastic sheet; (e) applying a stream of gas against a portion of said first surface of said first plastic sheet, so as to contact continuously, as said heated thermoplastic sheet is formed, said portion of said second surface of said first plastic sheet with said portion of said first surface of said heated thermoplastic sheet, thereby melt-bonding continuously said thermoplastic layer defining said second surface of said first plastic sheet and said heated thermoplastic sheet together, and thereby forming continuously a heated multilayered thermoplastic sheet having a first surface defined at least partially by said first surface of said first plastic sheet, and a second surface defined by said second surface of said heated thermoplastic sheet, said heated multilayered thermoplastic sheet having a temperature that allows said heated multilayered thermoplastic sheet to be thermoformable; (f) bringing said second surface of said heated multilayered thermoplastic sheet into contour matching contact with said interior mold surface of said first mold portion; (g) cooling said heated multilayered thermoplastic sheet thereby forming said shaped multilayered article, which retains said contour of said interior mold surface of said first mold portion; and (h) removing said shaped multilayered article from said first mold portion.