Method of forming a plastic unit having an outer plastic shell encapsulating a foam core

Claim 1

A method for forming a plastic unit using a molding apparatus having a carousel mechanism, comprising the steps of: a. clamping a first sheet of substantially rigid polyethylene material having a first thickness between a first fixed frame and a first moveable frame of a first frame assembly mounted to the carousel mechanism, so that the central portion of the sheet is unsupported by the frame assembly; b. clamping a second sheet of substantially rigid polyethylene material having a second thickness unequal to the first thickness between a second fixed frame and a second moveable frame of a second frame assembly mounted to the carousel mechanism, so that the central portion of the sheet is unsupported by the frame assembly; rotating the carousel mechanism to position the first and second sheets and frame assemblies intermediate at least two heaters slidably mounted to the molding apparatus and having a plurality of adjustably-positioned heating elements; d. heating the first and second sheets until the unsupported section of each sheet is flexible and sagging under force of gravity; e. rotating the carousel assembly to position the first frame assembly containing the first sheet over a first fluid-cooled mold section having a length, width, and a matrix of cavities defining mold protrusions designed to create voids in the formed plastic unit capable of receiving the tines of a fork-lift; f. lowering the first frame assembly containing the first sheet onto the first mold section so that the unsupported portion of the first sheet covers the cavities; positioning onto the first sheet a prefabricated solid foam core having a substantially flat top, a bottom comprising a matrix of protrusions substantially corresponding to and complementing the cavities of the first mold section, and a length and width slightly less than the respective length and width of the first mold section and aligning the core protrusions with the mold section cavities; h. mounting the second frame assembly containing the second sheet to the underside of a hydraulically-operated, moveable platen comprising a second mold section and positioning the platen over the first mold section; i. evacuating the first mold section so that the shape of the first sheet substantially conforms to the first mold section; j. lowering the platen onto the first mold section and compressing the core between the first and second sheets, thereby fusing the edges of the first and second sheets and encapsulating the core within the sheets to thermoform a plastic unit; k. permitting the plastic unit to cool; l. unclamping from the second frame assembly the second sheet forming a part of the plastic unit and raising the platen; m. unclamping from the first frame assembly the first sheet forming a part of the plastic unit; and n. trimming a portion of the fused edges of the first and second sheets forming parts of the plastic unit.

Claim 2

A method for forming a plastic unit using a molding apparatus having a carousel mechanism, comprising the steps of: a. clamping a first sheet of substantially rigid polyethylene material having a first thickness between a first fixed frame and a first moveable frame of a first frame assembly mounted to the carousel mechanism, so that the central portion of the sheet is unsupported by the frame assembly; b. clamping a second sheet of substantially rigid polyethylene material having a second thickness unequal to the first thickness between a second fixed frame and a second moveable frame of a second frame assembly mounted to the carousel mechanism, so that the central portion of the sheet is unsupported by the frame assembly; rotating the carousel mechanism to position the first and second sheets and frame assemblies intermediate at least two heaters slidably mounted to the molding apparatus and having a plurality of adjustably-positioned heating elements; d. heating the first and second sheets until the unsupported section of each sheet is flexible and sagging under force of gravity; e. rotating the carousel assembly to position the first frame assembly containing the first sheet over a first fluid-cooled mold section having a length, width, and a matrix of cavities defining mold protrusions designed to create voids in the formed plastic unit capable of receiving the tines of a fork-lift; f. lowering the first frame assembly containing the first sheet onto the first mold section so that the unsupported portion of the first sheet covers the cavities; positioning onto the first sheet a prefabricated solid foam core having a substantially flat top, a bottom comprising a matrix of protrusions substantially corresponding to and complementing the cavities of the first mold section, and a length and width slightly less than the respective length and width of the first mold section and aligning the core protrusions with the mold section cavities; h. mounting the second frame assembly containing the second sheet to the underside of a hydraulically-operated, moveable platen comprising a second mold section and positioning the platen over the first mold section; i. evacuating the first mold section so that the shape of the first sheet substantially conforms to the first mold section; j. lowering the platen onto the first mold section and compressing the core between the first and second sheets, thereby fusing the edges of the first and second sheets and encapsulating the core within the sheets to thermoform a plastic unit; k. permitting the plastic unit to cool; l. unclamping from the second frame assembly the second sheet forming a part of the plastic unit and raising the platen; m. unclamping from the first frame assembly the first sheet forming a part of the plastic unit; and n. trimming a portion of the fused edges of the first and second sheets forming parts of the plastic unit.