METHOD FOR FORMING AND BONDING THERMOFORMABLE COMPOSITES

摘要

A method for efficiently producing composite structures by thermoforming expanded thermoplastic honeycomb and extruded or co-extruded thermoplastic facing materials and bonding them with appropriate adhesives in a one-step, energy efficient and throughput-enhancing process, comprising the steps of: applying the appropriate adhesives in liquid, paste or film form to extruded or co- extruded sheets of thermoplastic material or to thermoplastic honeycomb; placing a pre-assembled composite in a closed mold tool, the pre-assembled composite comprising layers of facing, adhesive, thermoplastic honeycomb, adhesive, and facing, in that order; heating the pre-assembled composite to a temperature in the range of about 2000F to about 600°F at a pressure of about 0.1 to about 20 p.s.i.; thermoforming and bonding the pre-assembled composite into the final assembly; and cooling the composite to between about 70-150°F on the tool to facilitate release from the tool.