Patent GB-961053-A (GB)
Title: Improvements in or relating to the manufacture of laminated moulded articles of thermoplastic material
IPC: B32B27/00
Filed: 1961-07-05
Abstract: 961,053. Laminates and laminating; moulding hollow articles. LONZA Ltd. July 5, 1961 [July 8, 1960], No. 24346/61. Headings B5A and B5N. Hollow articles such as boats or boat parts, baths, vehicle body parts, refrigerator doors or railway carriage roofs are moulded from laminates comprising a layer of foam material with closed cells and cover layers, all of thermoplastic material such as polyvinyl chloride or copolymers thereof, polythene, or cellulose acetate, the layers having between them thermoplastic material such as poly-vinyl chloride/acetate or thermosetting material such as a polyester which adheres the layers together on heat pressing. Moulding is effected by clamping the assembled layers loosely between hollow frames and heat-pressing them between a male die and a female die or a peripherally clamped membrane, the clamping of the layers permitting them to be drawn inwards during the moulding process, irregular stretching and thinning of the moulded material being thus minimized. Substantial margins of material beyond the clamped areas are provided to allow for movement. As shown a casing 1 with removable cover 2 encloses an aluminium of other metal tank 18 surrounded by heating coils 22, and may also contain a fan or fans to ensure uniform heating. The tank 18 contains a base plate 20 having secured thereto a male die member 3 and four pillars 5. A plate 15, formed integrally with a female die member 4, rests on lugs 10 having secured thereto a clamping frame 7, both the plate and the lugs having holes through which the pillars 5 pass. The frame 7 comprises an upper frame member 8, secured to the lugs 10, and a lower frame member 8a secured in adjustable spaced relation to the frame 8 by outwardly-extending lugs on the frames connected by bolts and nuts, the bolts carrying spacer sleeves which can be selected to give the desired spacing and degree of clamping to the frames. Other forms of spacing members may be used. The pillars 5 are screw-threaded at their upper ends and carry sleeves 14 nuts 6 on which may be turned by spanner arms 6a to clamp the frame unit 7 and female die 4 down upon the male member 3. The die members may be made of metal or glass fibre reinforced polyester resin. In use, the moulding unit, comprising the base 20 and all parts supported thereon are first heated and then removed from the tank 18, the laminate components 12, 13, are then clamped between the frames 8, 8a, the spacing of the latter being selected to be about 4% less than the total thickness of the layers, and a wide margin of the components beyond the frames being provided to allow material to be drawn inwardly as it is deformed during moulding. The whole unit is then replaced, heating is continued, and the nuts 6 turned to clamp the upper mould part down on to the lower. On completion of the moulding operation the unit is removed, the mould cooled with water, and the moulding removed and trimmed, parts below a line such as A-A being removed as waste. Instead of the female die 4 a flexible membrane e.g. of rubber, may be peripherally clamped between a frame member replacing the plate 15 and a second frame member bolted upon it, the latter having an upturned inner edge corresponding to the periphery of the male die 4.