CN101044011A - Plastic composite articles and methods of making same - Google Patents

Abstract

The present invention provides a process for forming a shaped three dimensional article, comprising the steps of deforming an intermediate form (10), including a plurality of thermoplastic elongated members that are initially movable relative to each other, while displaceably clamping the intermediate form during the deforming in such a way that while a force is applied for deforming the intermediate form, the intermediate form is free to move within a predetermined limit; and optionally at least partially consolidating the thermoplastic elongated members of the intermediate form for forming a three dimensional article having a predetermined orientation of the elongated members. An apparatus including a press (32) for forming the shaped three-dimensional article is also disclosed.

Description

Manufacture plastic and strengthen the apparatus and method of synthetic products

Require priority

The application requires the priority of asking in the interim patent of the following U.S., and the application number of submitting on October 22nd, 1 is that 60/621,463 (agent is numbered 63863; 1062-041P1); The application number of submitting on September 16th, 2005 is that 60/717,965 (agent is numbered 63863B; 1062-041P2); The application number of submitting on September 16th, 2005 is that 60/718,025 (agent is numbered 64371; 1062-051P1); With submitted on October 11st, 2005 in please number be that 60/725,399 (agent is numbered 63863C; 1062-041P3) (express mail number be EV789808245US), these applications all are incorporated herein by reference.

The cross reference of related application

The application relates to co-applications, owns together, and (agent is numbered 63863D to be entitled as " the improvement polyolefine material that is used for the plastics synthetic "; 1062-41WO1); " plastics synthetic products and manufacture method thereof " (agent is numbered 63863E; 1062-41WO2); " improved microlayer structures and method " (agent is numbered 63863F; 1062-41WO3); (agent is numbered 63863G " to improve composite tube and manufacture method thereof "; Pending application 1062-41WO4); These applications all are incorporated herein by reference.

Technical field

The present invention relates to the manufacturing of moulding plastics synthetic products, and relate in particular to the manufacturing of three-dimensionally shaped plastics synthetic products, these goods comprise the intermediary of being made up of thermoplasticity extension component (elongated member) basically (intermediate form).

Background technology

Forming the moulding of plastic products from the plastic plate of general plane, for example by vacuum forming, or thermoforming, expectation but be difficult to control the whole wall thickness that obtains moulded products usually is particularly owing to inhomogeneous mobile result in the plate.

By having constitutional repeating unit, for example the moulding of the three-dimensional article made of the intermediary of the fabric of weaving into from plastic tape, the possibility of wall thickness change further improves.Particularly with loose form, the fabric that is made into from plastic tape for example, the ability of controlling the wall thickness of desired generation is complicated, this is not only owing to respectively carry the possibility of local attenuation, and be because the motion relative to each other in deformation process of phase adjacent band, and cause uncontrollable interband every, this can be in moulded products influence produce surperficial fineness, characteristic perhaps influences the two simultaneously.

An object of the present invention is to provide a kind of mechanism and method that is used to keep intermediary (intermediary that particularly comprises a plurality of extension components), make the controlled-deformation of this form when it is exerted pressure, produce.

Summary of the invention

The present invention relates to a kind of method that is used to form the moulding three-dimensional article, it comprises the mesomorphic step of formation, this intermediary comprises initially relative to each other movable a plurality of thermoplasticity extension components, simultaneously in deformation process, clamp intermediary movably (promptly, clamp intermediary by this way, make when applying when being used to be out of shape mesomorphic power, intermediary with respect to the structure that carry out to clamp function in preset limit (for example, laterally sliding distance is up to about 20% of the total stretching depth of distortion intermediary, 40%, 60% or higher) freely-movable); And partly solidified at least mesomorphic thermoplasticity extension component, be used to form the three-dimensional article of (orientation) extension component that has predetermined orientation.The invention still further relates to a kind of device that is used to form the moulding three-dimensional article, it is configured to allow intermediary to move (that is, laterally sliding) in deformation process.

Method and apparatus of the present invention provides a kind of scheme of uniqueness, and with in the plastics intermediary, particularly the balance in the intermediary of being made by thermoplastic belt flows.

Description of drawings

Figure 1A is the vertical view that expression is used for the mesomorphic device of moulding.

Figure 1B-1D represents to adopt the step of Figure 1A device.

Fig. 1 E is that another kind is used for the mesomorphic device of moulding.

Fig. 2 is the perspective view that is used for an example of installation frame of the present invention.

Fig. 3 A and 3B are the side cross-sectional, view of tool assembly used according to the invention, and it is in respectively and opens wide in starting position and the deformation operation process.

Fig. 4 A and 4B are the side cross-sectional, view of selectable secondary tool assembly used according to the invention, and it is in respectively and opens wide in starting position and the deformation operation process.

Fig. 5 is the perspective view that is used to carry according to an example of device of tool assembly of the present invention.

The specific embodiment

The present invention is devoted to find a kind of three-dimensional article manufacture method of uniqueness, especially for the three-dimensional intermediary of making goods to small part reinforcement (consolidated), for example be suitable for incorporation into the intermediary of moulding synthetic, this shaping synthetic comprises the intermediary such as polymer (and thermoplastic polymer) more specifically reinforcement material.The present invention though improved manufacture method is provided on the one hand, also provides the goods of being made by this method, and the machine that uses in this method.Can successfully make goods according to instruction of the present invention, for example need the goods of relative deep drawn and have goods circular even square or other sharp bights with relative complex profile.

Usually, the present invention is devoted to solve important problem in the prior art by a kind of method is provided, this method comprises moulding and strengthens mesomorphic basic step that this intermediary comprises a plurality of gathering extension components (the particularly parts of being made up of thermoplastic basically).Can reference sequences number be 60/621,463, title is: " plastics reinforcement synthetic ", the applying date is that on October 22nd, 2004, (agent was numbered 63863; 1062-041P1) (be incorporated herein by reference) and the U.S. Provisional Application on September 16th, 2005 number is 60/717,965, (agent is numbered 63863B; 1062-041P2), title is: the application (being incorporated herein by reference) of " plastics reinforcement synthetic ", and U.S. Provisional Application number is that 60/725,399 (agent is numbered 63863C; 1062-041P3), title is: the application of " extension component ", and a kind of parts of its ordinary representation, a size of these parts is (for example, length) (for example be longer than at least one other size, width, highly, thickness, or diameter), especially, the length of the extension component here is basically greater than (for example, at least big ten times or bigger) width or height.Therefore, the extension component here can include, but are not limited to from fiber, bar, rope, yarn, band, filament, the parts that belt or its are selected in making up arbitrarily.Be appreciated that in many aspects that from above film also can be calculated in the intended scope of " extension component ".The parts that also can comprise the decimal magnitude, for example whisker or platelet.Though " extension component " implication here can be very extensive, should be appreciated that the particularly preferred form of extension component will comprise one or more yarns especially, band, fiber and filament.Preferred extension component is the form of band.

In addition, should be appreciated that extension component of the present invention usually through handling reaching initial configuration, and be initial orientation state especially (for example, uniaxial tension, biaxial stretch-formed, perhaps other stretches, for example according to the ratio of stipulating herein).In obtainable a plurality of distinct advantages, when processing finishes, particularly in finished product, be implemented in basic ability of preserving initial configuration in the extension component according to theme disclosed herein.Thereby for example, when handling, the molecularly oriented of extension component begins basic reservation (for example, about at least 75% of reservation extension component initial orientation) from its initial configuration.

Therefore, extension component herein can include, but are not limited to from fiber, bar, rope, yarn, band, filament, the parts that belt or its are selected in making up arbitrarily.Also can obtain the parts of lesser amt level, for example whisker or platelet.Length to small part along extension component, these parts can be closely knit fully, part closely knit (for example, foaming), perforation ripples, distortion, or its any combination.

The size of extension component be generally make these parts can the manual operations.Yet more specifically, extension component is of a size of and makes it can mechanically actuated, is used to be processed into intermediary.For example, a specific examples of the present invention is described a kind of extension component, and for example yarn is with, fiber or filament have the thickness that is not more than about 1cm, and width perhaps all is not more than about 1cm, more especially be not more than about 0.5cm, even more especially be not more than about 1mm, and less than 1mm.For example, a kind of method is to use as yarn, band, and the extension component of fiber or filament, it has the width less than 5mm, less than the thickness of 1mm, more especially less than the thickness of 0.5mm (for example, approximately 0.01-0.25mm).

This extension component can be whole.It can be a homogenous material, multilayer material or its combination.The typical earth physical web of being made by polypropylene tape is the example of the fabric that is made into from this extension component.This extension component can have along this parts dimension and different characteristic or further features.On the one hand, this extension component can comprise the first surface part, the second portion adjacent with first, wherein first and second portion are in composition, polydispersity, form (for example, degree of crystallinity, orientation or both), melting rate, or its arbitrarily combination go up different.For example, a kind of ad hoc approach is described the extension component of at least one first thermoplastic, and have can be prior to the surface portion of oriented adjacent partial melting.

As sequence number is 60/621,463, and title is: " plastics reinforcement synthetic ", and the applying date is that on October 22nd, 2005, (agent was numbered 63863; 1062-041P1) (be incorporated herein by reference) and application number be on September 16th, 60/717,965,2005 application (agent is numbered 63863B; 1062-041P2), title is: the U.S. Provisional Application (being incorporated herein by reference) of " plastics reinforcement synthetic " and application number are that 60/725,399 (agent is numbered 63863C; The processed intermediary of making of at least one extension component, for example intermediary of selecting from coiling form, braiding form, volume pigtail form, random dispersion form or its any combination are discussed in U.S. Provisional Application 1062-041P3).As mentioned in this article, intermediary generally includes the construction unit of a plurality of repetitions.For example, intermediary can comprise the construction unit of a plurality of repetitions, the formation pattern of lining up, for example common or twills (for example herringbone, twill, hound-tooch, carreau or other twill), lace, satin weave or its any combination.The example of particular web comprises having the fabric that twines the extension component decorative pattern that the proportion of (for example, 2/1,2/2,3/1, or other ratio) extends in broadwise extension component above and below with 1/1 to 14/2.Thereby more specific examples of weaves includes, but not limited to 2/1 twill, 2/2 twill, four pieces of satin, 2/2 basket braiding, 5H satin weave, 8-H satin weave, or other fabric.Mesomorphic each construction unit can be relative to each other with any amount of possibility structural configuration.For example, overlapping unit can be vertical substantially each other.But, also can adopt the fabric of other desired angle.An attractive advantage that can obtain according to the present invention is that intermediary can be processed into and make the final molding goods keep constitutional repeating unit orientation relative to each other usually.

Usually, before any forming step, the adjacent structure unit can relative to each other motion in intermediary.A kind of method that realizes this point is to form intermediary, but does not make its experience strengthen forming step, irreversibly is engaged with each other by this step adjacent structure unit, and is for example bonding, fusing, fixing or other method assembling.Therefore, in the moment before the distortion of the treatment step according to the present invention begins, expect that especially intermediary is not reinforced, for example by more than the fusing point that is heated above at least a material in this form, so that fusion is opened in this material fusing, and weld effectively with adjacent cells.

Intermediary can comprise or be made up of individual layer (it optionally can comprise one or more patterns) basically.Intermediary comprises multilayer (it optionally can comprise one or more patterns) on their some or all respective surfaces.For example, the number of plies in the intermediary can from about 1 to 100 or more (for example, 2 to 65,5 to 50,10 to 40, greater than 10, greater than 20, perhaps other) range.Therefore, can expect intermediary under unstrengthened state, can have identical little thickness with single extension component, but also can be bigger, for example about 0.25mm is to the about 2.5cm or the bigger order of magnitude.Therefore, under strengthened condition, can expect that intermediary can produce about 0.8mm or be less to about 1.5cm or bigger thickness, for example from 0.1 to 0.8cm or more especially about 0.3 to 0.5cm.

If employing multilayer, then one or more layers can differ from one another aspect one or more, and for example thin layer, thickness, form or its any combination are strengthened, existed to the width of the heat treatment of the composition of material type, extension component, extension component, extension component, types of patterns, every layer whether.In order to illustrate, can be (for example from film, coating, solvent coating, extrusion coating or other), intermediary, winding form, braiding form, volume pigtail form, random dispersion form or its arbitrarily combination select at least one ground floor, it is in abutting connection with at least one second layer, this second layer from film, coating (for example is, solvent coating, extrusion coating or other), intermediary, winding form, braiding form, volume pigtail form, random dispersion form or its select in combination arbitrarily.As previously mentioned, the one deck at least in the multilayer can be reinforced in this explanation.No matter being on the entire area of this form or on its predetermined portions, also may be that a certain amount of plastics that flow not moulding or moulding (strengthen or do not strengthen) are placed between mesomorphic outside or the adjacent layer.At this moment, but can realize can local closely knit flowing stage fully, need not to use whole one decks nearby.Be further appreciated that from above and can optionally omit or change one or more layers part, make it possible to achieve the change of wall thickness or selectively change the regional area of goods.

Usually, extension component is a polymeric material, particularly thermoplastic.The thermoplastic of special top grade comprises at least a polyolefin (for example, polypropylene, or propylene-ethylene copolymers), for example can obtain from Dow Chemical, for example, is labeled as VERSIFY^TMThe perhaps polyolefin of INSPIRE .Sequence number is 60/621,463, and title is: " plastics reinforcement synthetic ", and the applying date is that on October 22nd, 2004, (agent was numbered 63863; 1062-041P1) (be incorporated herein by reference) and application number be on September 16th, 60/717,965,2005 application (agent is numbered 63863B; 1062-041P2), title is: the U.S. Provisional Application (being incorporated herein by reference) of " plastics reinforcement synthetic " and application number are that 60/725,399 (agent is numbered 63863C; Disclose other in U.S. Provisional Application 1062-041P3) and be applicable to the example of material of extension component.

The polymeric material of stretching material can be a homopolymers, copolymer, mixture or some other polymeric blends.For example, can adopt polypropylene homopolymer.As an alternative, perhaps except polypropylene homopolymer, a kind of example of copolymer comprises two or more different polyolefin, for example polypropylene, polyethylene copolymer.Other is suitable for comprising U.S. Pat 5,993 with the examples of material that is used as extension component in the present invention, disclosed band or rope in 711 and 6,045,923 (the transferring Lankhorst Indutech B.V.), in this combination as a reference.According to the former, the profile of extension component can comprise and is positioned at one or more lip-deep one or more longitudinal ribs and/or cannelure.According to the latter, extension component can comprise from other polyolefin blend of high density polyethylene (HDPE) and one or more prepares intermediate layer, thereby the quantity of high density polyethylene (HDPE) accounts for mainly, and for example 50% of overweight.More particularly, the intermediate layer is to prepare from following material, i.e. the high density polyethylene (HDPE) (＞940kg/m of 50-90% weight³) and (linearity) low density polyethylene (LDPE) (＜925kg/m of 10-50% weight³), ultra-low density polyethylene (＜910kg/m³), or these product combination.In addition, can exist a certain amount of polypropylene to improve the intensity of material.

Material of the present invention can provide the material behavior of certain limit.Unrestrictedly, for example, material according to the invention can show at least approximately elastic modelling quantity of 13GPa, and more especially about at least 18GPa, measure by ASTM D-638, at least approximately the hot strength of 150MPa, and more generally about at least 300MPa is measured by following ASTM method of testing D-638.

For example when middle form is individual layer, and for example when expectation has multilayer as mesomorphic part, one or more layers can be through handling to prevent single structure unit, each layer or both separation.For example, for the single or multiple lift form, can guarantee that one or more layers (and fixed to one another alternatively for the multilayer form) in these layers is in suitable mode, for example by making the construction unit thermally coupled along, two of this form or at least a portion on many limits.Also can adopt other processing method, for example mechanical step (for example, crimping, fixing, net dress, riveted joint, sew up or other method), adhesion step (for example, by dripping an adhesive, adhesive tape or other method) or combination step.By this way, can operate this intermediary at an easy rate, for example be used in the tool cavity transportation, store, move, reduce the possibility that the single structure unit is separated into the degree of infringement intermediary globality simultaneously.

That derives from understanding an advantage of the invention is, when adopting oriented polymerization material commonly used to be used for extension component of the present invention, usually has the heat treatment window, can make material deformation therein, but material roughly keeps its microstructure orientation therein, thereby as the result of the step process according to the present invention, material roughly keeps its mechanical property.

Therefore the invention provides a kind of convenience and mode reliably, in the material hot treatment window, operating, predict and the characteristic of reproduction thereby allow in produces goods, to have.

As previously mentioned, for goods constructed in accordance, intermediary is provided and,, control is relatively accurately implemented in mesomorphic distortion by this method according to a kind of method operation.Desirably, when middle model deformation, pay special attention to control the wall thickness of the three-dimensional configuration that produces, extension component orientation relative to each other, molecularly oriented or its combination of extension component Molecularly Imprinted Polymer in the generation three-dimensional configuration.

Here can adopt such operation, by this operation, intermediary before moulding and strengthening, rigidly fixes (for example, clamping) nearby or on any limit., still, a kind of particularly preferred method is included in and supports intermediary in the forming process, makes this form removable in deformation process (for example, with respect to any setting tool this form being slided).By example,, can expect thatintermediary 10 will be installed in the suitable structure 12 (for example, framework) with reference to figure 1A-1D.Shapingjig 14 will makeintermediary 10 be out of shape (for example, towards mould 16) effectively, produce at least one formingarea 18 and theperipheral region 20 that roughly is connected forming area (for example its outside).Usually thisstructure 12 comprises one or more bias components 22.The bias component of any employing is selected usually and is located such that they can apply bias force, and this bias force is in response to the power that is realized by intermediary when the middle model deformation.At this moment, adopt this biasing mechanism to be used on the direction of the power that is parallel to any warp tool, providing bias force (for example, shown in Fig. 1 E) usually.Can also adopt, during the cycle of the warp tool application of force, be used for providing bias force (also can adopt the two combination) in vertical direction.This bias component can be connected directly to intermediary and come shaped device, installation frame (as described herein) or other to be suitable in the intermediary acting in conjunction, is used for the structure that moves in mesomorphic deformation process control.Can use any suitable mechanism to realize biasing.Example comprises spring, magnetic valve or other calutron, piston and its any combination or flexible, reciprocating any other similar workpiece.

The example of the ad hoc approach of a kind of moulding intermediary (no matter being individual layer or multilayer) comprises employing resilient (for example, the spring biasing) structure, and for example whether no matter the load on spring framework strengthened, and it carries intermediary 10.For example, shaping jig hastool mould 22, has the framework form between them.The intermediary attenuation that the elasticity of intermediary fixed structure takes place when helping avoid usually there not being framework moulding, thereby help to produce the intermediary of moulding, it comprises the wall thickness and the smooth exposed surface that does not have gauffer of constant on roughly whole available parts of generation form.

Should be appreciated that the different structure that can adopt instrument, be used for successfully being out of shape necessary desired fixing and mobile combination.For example, a kind of specific method schematically shows in Fig. 1 E, and its middle frame itself is flexiblely installed (for example passing through spring), makes the intermediary moulding to allow construction unit to flow, to keep wall thickness in the process of exerting pressure simultaneously.Elasticity is installed and can be made framework hang (for example, the weight of spring and any other clamp mesomorphic optional power movably) by one or more springs, this framework be mounted to make its in deformation process towards intermediary or its combined bias.

Should be appreciated that for the multilayer form of every layer can relative to each other move in the above (for example, sliding independently of one another), can adopt this device, be used for all keeping consistent amount of exercise in this form under the load effect.

Illustrate in greater detail roughly method of the present invention below with reference to Fig. 2-5.According to such method, shown in Figure 1A-1E, be chosen in and be used to handle mesomorphic condition in the deformation process, make and in forming area, realize in check distortion, and more specifically, obtain wall thickness relatively uniformly in desired place, roughly keep extension component orientation relative to each other, avoid being used for mesomorphic orientated polymer form, the extreme deviation of degree of crystallinity or both (and the characteristic that produces), on whole forming area roughly, produce smooth, non-wrinkled exposed surface, realization (for example is approximately 0.1: 10 to about 5: 1, about 1: 1) draw ratio (the parts degree of depth is to the relation of width), the mesomorphic layer of multilayer allows relative to each other to move, and avoids extension component basically owing to excessively extend the damage that causes, or its combination (being preferably above-mentioned whole combination) arbitrarily.For example, a kind of ad hoc approach is to be controlled to fix mesomorphic power in the deformation process.That is, roughly described with respect to Figure 1A-1E, this power is selected as required and is changed, and makes mesomorphic peripheral region experience moving to small part in response to the power that is occurred in the forming process.For purposes of illustration,, represent moving of horizontal slip form, can see that the transverse movement of the some A on intermediary is with respect to permanent datum X with reference to figure 3A and 3B.

With reference to figure 2-4 explanation according to a specific examples that is used to allow the system of peripheral region motion of the present invention, (not the having restricted) of in as shown in Figure 5 equipment roughly, being adopted particularly.Can see that in order to help mesomorphic operation, intermediary can be arranged in suitable carriers framework 26.For example, do not have restricted ground, Fig. 2 represents support, and it comprises at least one bracket component, and more specifically comprises a plurality of separable coefficient bracket components, for examplefirst bracket component 28 and second bracket component 30.Though first bracket component and second bracket component can (for example be configured for holding intermediary by other structure, can have similar size toward each other around them), but a kind of attractive method comprises the bracket component that adopts different size, allow a bracket component to be arranged in another, and intermediary is between bracket component.Particularly with reference to figure 3A and 3B, a kind of such method is to form contained structure (for example, the borehole wall, groove, ledge etc.) in one of bracket component, and the protuberance of another parts (for example, pin, flange, wall etc.) can penetrate in this contained structure.But usually, the structure of coefficient bracket component makes that intermediary will not be fixed in its position when middle form is placed in the support, but can respond deformation force and move (for example, by horizontal slip).

Usually, adopting support, carrying at least a portion inentire circumference zone 20 in the mesomorphic situation greatly usually,Support frame 26 will become and have an opening, and warp tool can pass this opening in processing procedure.Intermediary can be carried by support and be made this form and support contact on some or all of support.Though the embodiment of Fig. 2 A and 2B has represented a kind of enclosed construction, Support frame also can be divided into the parts of a plurality of lateral separation.The coefficient bracket component that separates is physical connection each other alternatively, for example by connections such as one or more pivotal parts (for example, hinge), fixture, magnet or its combinations.

Forward Fig. 3 A and Fig. 3 B to, also, represented a kind of method, can in deformation process, arrange intermediary by this method with reference to figure 5 (example ofexpression forcing press 32).As shown in the figure, can realize distortion by using shaping jig (for example, punch die 34), shaping jig will act on the relative shaping jig (for example, thetool mould 36).Blank holder 38, have near the warp tool of being arranged in (that is) exposed wall surface 40, punch die 34,mould 36 or both peripheral outer, and can be mounted for respect to punch die 34mould 36 or both self-movements.In the illustrated embodiment, punch die 34,mould 36 or both can removably separate (for example, it can removably be fixed on correct position by vacuum, fixture etc.) on corresponding platen or other supportingconstruction 44 and 46.Can also make instrument and platen be combined into single structure.And the size of wall surface can be provided with or adopt other structure, makes it support one ormore bracket components 28 or 30.

As mentioned above,blank holder 38 can be mounted to and be independent of the shaping jig translation, and is used in deformation process fixing intermediary movably.Preferably,blank holder 38 is configured to make its fixing intermediary rigidly not in deformation process.Like this,blank holder 38 can comprise one or more protuberances 42 (for example, cyclic lug), and it is suitable in deformation process contact and fixing intermediary movably.Can combine withSupport frame 26 with mesomorphic this contact, or be independent of any Support frame.(not shown) in another embodiment, blank holder are configured to replace or except direct contact intermediary, the supporting bracket framework.

Blank holder 38 can independently in any suitable manner be installed.But, have been found that a kind of method helps to realize that the expectation of intermediary in this device is mobile in deformation process, according to top instruction, carryblank holder 38 by this method.That is, blank holder (combining separately or with Support frame) constitutes the elastic frame assembly effectively, and it allows flowing of mesomorphic absolute construction list cloud, to keep wall thickness in the process of exerting pressure.Elasticity is installed and can be realized in many ways.For example, as mentioned above, blank holder can hang (for example, the weight of blank holder and any other clamp mesomorphic optional power movably) by one or more springs, this blank holder can be mounted to make its in deformation process towards intermediary or its combined bias.

A kind of particular preferred approach, as shown in Figure 3A and 3B, and Fig. 5 represents a kind of method, by one ormore axle 48 vertical hangings,blank holder 38 can be alongaxle 48 fixing or freely-movables by this method for blank holder 38.One or more bias components (for example, spring) 50 are arranged to be used for to intermediary (Fig. 5 does not represent) biasing blank holder 38.This bias component is chosen to make them to apply as intermediary is enough to engage movably intermediary (with optional any Support frame), be enough in deformation process, allow intermediary to pass the amount of the composition surface of blank, Support frame or both mobile expectations, the power of resistance to deformation simultaneously makes intermediary keep fixing fully, makes mesomorphic distortion to produce.

Thereby the selection of bias force can realize by the mesomorphic desired characteristic of considering institute's moulding.Thereby the moulding form that is produced, in the certain limit of draw ratio, can all realize predetermined wall thickness in the moulding form, extension component orientation relative to each other will roughly be preserved, avoid being used for mesomorphic orientated polymer form, degree of crystallinity or both extremes of (and the characteristic that produces) depart from, on whole forming area roughly, produce smooth, non-wrinkled exposed surface, realization (for example is approximately 0.1: 10 to about 5: 1, about 1: 1) draw ratio (the parts degree of depth is to the relation of width), the mesomorphic layer of multilayer allows relative to each other to move, and avoids extension component basically owing to excessively extend the damage that causes.

In the selection of bias force, can consider other factors.Alternatively, can select certain bias force, and one or more processing parameter can respond selected bias force and change.For example, ad lib, can also change the speed that warp tool moves, change the load in the circulation, change the temperature in the cyclic process, change quantity or its any combination of load cycle.

Usually, the moulding that produces in the step of being represented by Fig. 3 A and 3B will be carried out in the temperature that raises, for example, provide mesomorphic material the softening temperature that surpasses room temperature, and be in the temperature that is higher than the material melting point on the extension component outer surface in the intermediary potentially.Thereby shaping jig parts, platen, this installs any other associated components, or its arbitrarily temperature of combination can control as required.The temperature of two or more parts can independently be kept.For example,platen 44 can be heated or turn cold, and is used for heating or cooling forming instrument (for example, punch die 34).Can comprise the3rd platen 52, be used for when the moulding instrument is in retracted position, heating or cooling forming instrument (for example, punch die 34).Relative shaping jig (mould 36) also can be heated or cooled.For example,second platen 46 can be suitable for cooling off or heating the shaping jig (for example, mould 36) that is arranged in wherein.According to expectation,heat guard 54 can be arranged between the parts of this device, is used to keep discrete thermal region.Should be appreciated that, mesomorphic temperature can be in one or more predetermined period of times in any deforming step (for example, about at least 5 seconds to about one hour, and more preferably about 30 seconds to about 5 minutes; Also can adopt the longer or shorter time) the maintenance constant.Can also in certain temperature range, change, be used to realize the feature of expecting.And intermediary can be preheated to the first predetermined temperature and remain on this temperature in deformation process, perhaps heating or be cooled to different temperature in deformation process.

According to top described, with reference to figure 3A and 3B, mesomorphic as can be seen distortion can realize that it is arranged to make intermediary to be arranged between therelative part 34 and 36 of shaping jig then bySupport frame 26 thatintermediary 10 is packed into.By making the feeding and apply load towards each other of shaping jig each several part to intermediary.Any joint that blank holder 38 (for example, using protuberance 42) will engage intermediary and be made of Support frame 26.Can see thatblank holder 38 can be suitable for (for example, by its size, operating parameter or other) and make blank holder engage intermediary in the moment of any satisfaction.For example,blank holder 38 can at first engage intermediary and is used for before deformation load takes place, simultaneously or later resistance to deformation load.

Can see when applying deformation load, and at least after distortion beginning, mesomorphic peripheral region will be supported by blank holder 38.But bias force will allow the peripheral region transverse movement.This is represented by the relative motion with respect to the reference point A of reference point B among Fig. 3 A and the 3B.

Mesomorphic controlled motion in the deformation process helps mesomorphic material to enter the control of the amount of forming area, helps avoid excessive material and stands to fold or wrinkle.And, in deforming step, particularly under the pressure condition of temperature that raises and shaping jig, may produce mesomorphic reinforcement.Thereby, can also see, if expectation can be eliminated and strengthen mesomorphic independent step before moulding.Reinforcement can be carried out in any suitable manner, and can carry out in the operation in independent stage or carry out as the part of multistage operation.In the process of strengthening, usually, be initially at fold is arranged on himself intermediary (for example, this form itself is pliable, the adjacent structure unit is relative to each other movable, perhaps the both is) be reinforced, it is semi-rigid at least that this form will become, and preferably makes it can support himself weight.Usually when moulding and reinforcement, form of the present invention can be to keep shape for a long time, for example under home, surpass for 2 week, more especially surpass one month, even especially above 3 months.By this way, can expect that intermediary manufacturer can produce mesomorphic stock, be assembled in synthetic up to needs its period that can store prolongation.The intermediary of strengthening, particularly those comprise that polyolefin as its main component, will show from about 0.75 to 0.9g/cm usually³Reinforcement density, and about 0.83g/cm more especially³Also preferably strengthen the density that form shows about at least 80% solid density, more preferably the density of about at least 90% solid density (for example, being higher than 95% of solid density, for example at least 99% solid density).

Strengthening treatment step will irreversibly link together the adjacent structure unit effectively, thereby can strengthen by bonding, fusing, fixing or other step of assembling these unit.An ad hoc approach that carries out easily according to the present invention is, intermediary is heated above the temperature of at least a material melting point in this form, so that material fusing and fusion, and weld with adjacent cells effectively.

Heating steps can use the method for any amount to carry out.For example, this form can preheating and be sent to the anamorphic attachment for cinemascope that is in higher temperature a long way off before distortion, applies rock deformation pressure on anamorphic attachment for cinemascope.In addition, perhaps substitute as a kind of of preheating step, heating can occur on the anamorphic attachment for cinemascope or be in the anamorphic attachment for cinemascope.For example, punch die, mould, its combination or other instrument that is used to intermediary is out of shape can be preheated.In one approach, if adopt the off-line preheating, then the temperature in the intermediary will be increased to the required processing temperature that it is in tool interior., convection current, radiation or its arbitrarily combination carry out.Stove can be used as thermal source.Radiofrequency heat source, the thermal source of radio frequency (radiofrequency) also can be used as thermal source.Heating can be at inert gas, carry out at air or in gas that other is fit to.In addition, heating steps can comprise a plurality of steps, and each step is carried out under different temperature, and each step is carried out applying under the different pressures, or the combination of these conditions.

For example, unrestrictedly, for based on mesomorphic polyolefin, preheating step (if employing), can be by when not applying deformation load, intermediary being heated to about at least 60 ℃, and be preferably lower than the temperature of about 120 ℃ (for example, about 100 ℃).This can keep a lot of minutes, even one day or longer (for example, about 0.5 to 20 hour).Afterwards, can apply deformation load, preferably when this intermediary be heated (for example from about 120 to 160 ℃ (for example, about 140 ℃) or higher), for example be used to realize the rock deformation pressure of about 10 to about 200Bar (for example, about 20 to about 140Bar, and more especially about 80Bar).The temperature and pressure that raises is kept about 1 to 10 minute, and more especially about 3 to 5 minutes (for example, about 4 minutes), makes can take place to strengthen and distortion.According to mesomorphic size, can realize the longer or shorter time, and/or can adopt higher or lower pressure that top scope can be used for strengthening the extremely intermediary thickness of about 1 to about 10mm (for example, about 2 to about 7mm) usually.

Turn to Fig. 4 A and 4B, represent the example of optional secondary modification operation.Especially, the moulding of article according to the invention can expect and adopt secondary punching operation, and trimming for forming step more especially.This secondary step can be carried out under the temperature of one or more risings, but more generally conduct in room temperature or below the room temperature (for example, from about 0 to 20 ℃, and high more especially to about 15 ℃).In the moment of secondary forming operation, the near small part of intermediary is strengthened (for example, the heat by comprising in the operation of representing among Fig. 3 A and the 3B) usually.But, also may strengthen in the second forming operation process, producing, particularly in secondary forming operation process, about 0.5 to about 5 minutes (for example, about 1.5 to 3 minutes) lasting pressure can be about order of magnitude of 50 to about 250Bar, and be more particularly about 100 to about 200Bar (for example, about 175Bar).Therefore, consider foregoing,Support frame 26,blank holder 38 or both uses can be omitted.By other embodiment here, be appreciated that and consider these instructions that promptly foregoing is not used in covering and can adopts all occasions of the present invention.Can be according to needed result, base substrate size to be processed, to handle the relevant item of properties of materials parameter is changed with other.For example, can adopt the longer or shorter time, than the higher or lower pressure of being quoted in the above-mentioned discussion.

A kind of possible operation of secondary forming operation is can be in the forming step process, the additional strain sclerosis that takes place in intermediary (can be recognized at elevated temperatures, before strengthening or in the process, can adopt about 10 to about 40% strain extension), thus make the goods of moulding have improved mechanical property.For example, strain is extended and to be kept below about 15% and more preferably be lower than 10%.Therefore, secondary forming operation can adopt with primary operation in different size shaping jig (it is configured to cool off in forming process alternatively) and take place.Can also adopt the instrument identical with primary operation, but as intermediary in primary operation after-contraction or lax result, on instrument/intermediate form interface, produce the gap, the space that can additionally be out of shape is provided.In another approach, can be very close to each other, thus mesomorphic material also further is compressed between the instrument that is used to realize further strengthening, the perhaps local densification in the desired region.In another approach, adopt secondary operation to be used for keeping depositing the mesomorphic size and the profile of cooling procedure moulding.Any combination of the step that can adopt in this section to be quoted.

Thereby according to Fig. 4 A and 4B, one ormore instruments 60 for example can replace at least one shaping jig among Fig. 3 A and the 3B in conjunction with at least one instrument of 62 of cutting edge.Alternatively, the alternative instrument 36 ' that is carried in the platen 46 ' also can be replaced.Making the intermediary distortion as can be seen and need not heating, is the getable advantage of the present invention with softening thermoplastic component material.

Can see that using another advantage of the present invention is energy products of press forming (no matter being symmetry or asymmetric in shape), need ability minimum or that do not have additional completion step.This also provides the advantage that reduces follow-up cutting operation.Punch steps can also adopt suitable pressure, makes mesomorphic reinforcement take place in punching course.Should be realized that punching press not only can be cold stamping.Also may be under the rising temperature punching press heated form.

When adopting the multistage to be used for moulding form of the present invention, can adopt a plurality of independent forcing presses.Can also be configured to the instrument of single forcing press, it is implemented in the combination of performed function in the independent stage.

The simplification advantage of this method is only by selecting suitable interchangeable bias component (for example spring), and the further performance by using mesomorphic ability that single assembly distortion different size, profile, complexity, material behavior etc. have a wide reach.In order to reach this point, here the selection that has realized that suitable biasing element can be by (for example determining threshold stress, surpass mesomorphic extension component and do not expect the stress of ground plastic deformation) and realize, and select bias component to make it only (for example to middle form, regional around) apply enough power, this mesomorphic lateral displacement will realize that threshold stress take place in the past.

Supporting intermediary can realize its movable mode in forming process by the process for selective of any amount.For example, a kind of method roughly adopts on every side in the zone that is used for the one or more physical displacement dampers of moulding.For example, intermediary can comprise the variation of surface appearance, protrusion of surface etc., and it can provide resistance when the relative parts relevant with instrument contact.This damper can be configured to make it to spur the instrument that passes gradually under threshold pressure.

Another kind method can apply at least a portion continually varying clamping force (for example, by machinery, dynamo-electric or electromagnetism clamp mechanism) to intermediary, makes the intermediary distortion simultaneously.Clamping force can circulate, and for example makes, when distortion took place, clamping force temporarily reduced, and temporarily reduces in the process at this, and intermediate form can move, and wherein when clamping force was restored, intermediary reverted to fixedly peripheral region.Applying the step at intermittence that the power of fixing to clamp and power reduces can repeat in the regular or erratic cycle as required.

Be not used for limiting, a specific examples of the present invention comprises the device among Fig. 5.In addition, the same with herein other example, can under the situation of considering these instructions, understand, this example is not used in covering can adopt all occasions of the present invention.Can be according to needed result, base substrate size to be processed, to handle the relevant item of properties of materials parameter is changed with other.Six carbon steel springs arrange around this device, are used for when it is arranged between first and second shaping jigs towards the intermediary blank holder of setovering.Each spring is rated at every centimetre of (cm) of 32.16 (N/mm) (that is, specified every millimeter (mm) every centimetre (cm)).Suppose the initial length 130mmLO of each spring, the compression spring constant is embodied as 32.16[(N/mm/cm)]/13[cm]=2.47[N/mm].Suppose each spring compression 76mm, the power that each spring applies obtains to be 76mm * 2.47[N/mm]=188[N].

For example, when middle form realizes this power during moulding at elevated temperatures, the whole power (F) that distribute on this form are if it is produced F=188 * 6[N by the blank holder spring]=1128N.

Use this power, this device can be easy to that (for example, area is about 350 to about 550cm at the relatively large blank that is produced by the multilayer intermediary²) (for example, about 1: 1) deep drawn was than (relation of the degree of depth and width), and wherein this intermediary is made by about 14 to 34 layers of woven polypropylene sheet in about 0.1: 10 to about 5: 1 to go up extrusion.It also is used to prevent reverse, and not only anti-sliding stop.

In this example, Support frame is of a size of every side 22.5cm, and the about 13mm of perimeter wall that limits inside opening is wide.This produces about 0.011m²Area.If support bears whole pressure separately, this equals the pressure of 102kPa or 1Bar.Also act on the entire area of blank holder contact if suppose this power, then this masterpiece is used in 0.051m²Area on, then pressure is actually 22.3kPa or 0.22Bar.

Should be appreciated that in a particular aspects of the present invention, a lot of above-mentioned characteristics are results of material selection and treatment conditions combination, these treatment conditions cause keeping grown form (and specific orientation) in mesomorphic extension component composition in whole treatment steps, finish up to moulded products.Especially, a kind of method of the present invention had been avoided mesomorphic any reinforcement step before thermoforming punching press or other intermediary forming step.The material of front will adopt the reinforcement step in the past at any intermediary forming step.But this maintenance to orientation is not compulsory for a lot of novel embodiment disclosed herein.Therefore, those skilled in the art will recognize that, multiplely adopted the prior art material of strengthening step still can be used for making the synthetic of these embodiment in the past at the intermediary forming step.In addition, can adopt the multilayer intermediary, all some in the layer are used for keeping orientation through handling.

Here " first " that relates to and " second " are not used in restriction only by first and second combinations that constitute.In related occasion, theme of the present invention can suitably comprise the the three, the four or more multinomial." extension component " that relates to is not used in gets rid of multiple extension component.Except what stated, using does not need to strengthen fully or moulding such as " reinforcement " or " moulding " or its coefficient treatment step; Also can strengthen or moulding by desired part.And disclosing of " " or " one " element or step is not used in eliminating extra element or step.

Unless stated otherwise, the size of various embodiment described here and profile are not used in restriction the present invention, can adopt other size or profile.Can provide a plurality of structures to form step by single overall structure or step.As an alternative, single overall structure step can be divided into independent a plurality of parts or step.But function also can be integrated into single parts or step.

In addition, though feature of the present invention may be only explanation among in the illustrated embodiment one, these features can combine with one or more further features of other embodiment, are used for any given application.Be further appreciated that from foregoing the manufacturing of the unique texture here and its operation also constitute treatment in accordance with the present invention.

It is exemplary rather than restrictive to should be appreciated that above-mentioned explanation is used for.Except a lot of embodiment of given example be applied in much that to have read after the above-mentioned explanation be conspicuous for those skilled in the art.Thereby scope of the present invention should not determine according to the above description, and should determine according to appended claim, requires the right with the four corner of these claim equivalences yet.All disclosing of Zhang Wen and reference comprises patent application and open, in conjunction with as a reference, is used for whole purposes.Disclosed herein is not abandoning of this theme to the omission in the claim under any aspect of theme, should not be considered as the part that the inventor is not considered to this theme disclosed inventive subject matter yet.

Claims (21)

1, a kind of method that is used to form the moulding three-dimensional article comprises the following steps:

Make the intermediary distortion, this intermediary consists essentially of a plurality of thermoplasticity extension components, clamps intermediary simultaneously in deformation process by this way, and promptly when the power of applying was used to make the intermediary distortion, intermediary is freely-movable in predetermined threshold; With

Alternatively, strengthen mesomorphic thermoplasticity extension component at least in part, be used to form three-dimensional article.

2, method according to claim 1, wherein the thermoplasticity extension component is for comprising polyacrylic band.

3, method according to claim 1 and 2, wherein the step of strengthening at least in part takes place in the deforming step process.

4,, wherein movably clamp by spring biasing blank holder and carry out according to the described method of claim 1 to 3.

5,, also comprise intermediary is preloaded in the Support frame, and in the deforming step process, make intermediary remain on step in the Support frame at least according to the described method of claim 1 to 4.

6, according to any described method in the claim 1 to 5, also comprise intermediary is heated to such temperature, make intermediary extension component middle body keep below its fusing point, but fully softening so that distortion and in deformation process, avoid extension component to break.

7, method according to claim 6, wherein extension component has the molecular moiety of orientation.

8, method according to claim 7 wherein keeps heating-up temperature, makes being oriented in the deforming step of extension component alignment portion roughly keep.

9,, also comprise the step of this form of side cut punching press according to any described method in the claim 1 to 8.

10, method according to claim 9, wherein deforming step and side cut punch steps use common forcing press to carry out.

11, method according to claim 10 also is included as deforming step and side cut punch steps and adopts at least two movable instruments of independence.

12, method according to claim 11 also comprises the movable instrument of these at least two independences was arranged on the mesomorphic same side in the past in distortion and punch steps.

13, method according to claim 11 also comprises the movable instrument of these at least two independences was arranged on the mesomorphic not homonymy in the past at shaping and deformation and punch steps.

14, method according to claim 9, wherein deforming step and side cut punch steps are carried out on the forcing press that separates.

15,, also comprise changing mesomorphic thickness, but be used to form final three-dimensional article with variable thickness according to any described method in the claim 1 to 14.

16, according to any described method in the claim 1 to 16, wherein intermediary comprises multilayer.

17, a kind of method that is used to form the three-dimensional article of moulding comprises the following steps:

Make the intermediary distortion, clamp intermediary simultaneously by this way in deformation process, promptly when the power of applying was used to make the intermediary distortion, intermediary is freely-movable in predetermined threshold; With

Strengthen this intermediary at least in part; With

This intermediary of punching press in secondary forming operation alternatively.

18, method according to claim 17, wherein punching press comprises the side cut punch steps.

19, a kind of device that is used to form three-dimensional article comprises:

A) be used under the rising temperature, making first instrument of intermediary distortion;

B) be used for mesomorphic optional second instrument of punching press; With

C) be used for clamping mesomorphic support by this way, make that intermediary is freely-movable in predetermined threshold when the power of applying is used to make the intermediary distortion in deformation process.

20, device according to claim 19, wherein this support comprises a plurality of bias components, these bias components are parallel to this support of biasing in the direction of the first movement of tool direction in device.

21, a kind of goods of making according to the arbitrary described method of claim 1 to 18.

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