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Selectively-reinforced-thermoformed-article-and-process

Extrusion of an article of varying content

I claim: 1. A process of extruding an extrudate with different materials, the proportions of which ...

Method for cooling and if necessary calibrating articles of plastic

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High precision multiple-extrusion of confectionary products

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Method and apparatus for producing a braided puff extrudate

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Apparatus for producing a curly puff extrudate

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Method and apparatus for producing a curly puff extrudate

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Dross compression apparatus including a cooling system for cooling the compression head and cooling method

The compression head of the dross compression apparatus is more effectively cooled in accordance ...

Polyester film composites

I claim: 1. A polyester film composite, which comprises a primary layer comprising a highly ...

Polyester film for thermal lamination

OF THE INVENTION The polyester A in the present invention must have ethylene terephthalate and/or ...

Selectively reinforced thermoformed article and process

Details

Inventors: Breezer, Harlon W.; Price, William F.;
Assignee: TriEnda Corporation (Portage, WI)
Primary Examiner: Watkins, III; William P.
Assistant Examiner:
Attorney, Agent or Firm: Lathrop & Clark LLP

A process is disclosed for producing reinforced twin-sheet thermoformed articles comprising the steps of heating first and second sheets of thermoplastic material; forming the sheets in molds; heating a reinforcing insert of thermoplastic material; placing the heated insert on the first sheet in its mold at the location to be reinforced; pressing the second sheet into contact with the heated first sheet and the heated insert to form the insert between the sheets so that a fusion of the thermoplastic sheets and the insert takes place to produce a reinforced section of the article having a desired shape and thickness. Alternative processes are disclosed wherein a heated quantity of thermoplastic liquid material is extruded or injected between the first and second sheets within the first and second molds either by inserting the liquid material before the molds are closed or by injecting it through one of the molds. Also disclosed are twin-sheet thermoformed articles with reinforced sections which are thicker than the combined thicknesses of the two thermoformed sheets at a particular location. The articles may advantageously be reinforced with plastic identical to the plastic of the two sheets. The articles are also easily recycled as they are entirely plastic with no non-plastic matter included.

DETAILED DESCRIPTION We claim: 1.
A reinforced twin-sheet thermoformed thermoplastic article comprising: (a) a first thermoformed thermoplastic sheet; (b) a second thermoplastic sheet; and (c) a quantity of solid thermoplastic material located between and fused to the first and second thermoplastic sheets at a reinforced section of the article such that the reinforced section is of greater thickness than the combined thickness of the first and second sheets at the section location, and wherein the first thermoplastic sheet is fused to the second thermoplastic sheet without an intermediate sheet at locations other than at the reinforced section of the article.
2.
The article of claim 1 wherein the first sheet, the second sheet, and the quantity of thermoplastic material are all formed of the same thermoplastic material.
3.
A reinforced twin-sheet thermoformed thermoplastic article comprising: (a) a first thermoplastic sheet having at least a portion thereof thermoformed; (b) a second thermoplastic sheet having at least a portion thereof thermoformed, wherein the thermoformed portions of the first and second sheets define a cavity; and (c) a solid thermoplastic reinforcing insert molded to substantially the same shape as the cavity and fused to the thermoformed portions of the first and second sheets.
4.
The article of claim 3 wherein the first sheet, the second sheet and the insert are all made of the same thermoplastic material.
5.
The article of claim 3 wherein the first and second thermoplastic sheets are fused directly to one another in at least one location.
6.
A reinforced twin-sheet thermoformed thermoplastic article comprising: (a) a first thermoformed thermoplastic sheet formed to have an upwardly opening cavity; (b) a second thermoformed thermoplastic sheet having downwardly extending portions which open upwardly, said downwardly extending portions overlying the upwardly opening cavity of the first sheet, wherein portions of the first sheet are fused directly to portions of the second sheet spaced from the cavity; and (c) a quantity of solid thermoplastic material disposed within the first thermoplastic sheet cavity and fused to both the first thermoplastic sheet and the second thermoplastic sheet and molded into the shape of the cavity by the first sheet and the second sheet

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