Abstract Ribbed structure laminate is provided comprising a film of thermoplastic resin heat-bonded to the tops of a plurality of ribs which are in turn integrally molded at their base with another film of thermoplastic resin, with the junction between the first-mentioned film and the tops of the ribs being in the form of a smooth transition between the film and a flange formed along the top of each rib. The laminate is useful as a material of construction such as for packaging, heat exchangers and insulation. The laminate can be made by maintaining the ribs in contact with a heated release surface so as to form a molten flange along the top of each rib, progressively removing the molten flanges from the release surface, and progressively contacting the molten flanges with a film of heated thermoplastic resin. This process is also applicable to the bonding of other thermoplastic resin objects, surface-to-edge or edge-to-edge, together.
A process for heat bonding an edge of a first thermoplastic resin object to an edge or surface of a second thermoplastic resin object, comprising advancing said first object along a path with its edge in contact with a heated release surface moving therewith to melt its edge, said first object being under compression against said release surface whereby said molten edge forms into a flange thereagainst, progressively removing the said first object and thereby the molten edge in the form of a flange from said release surface, and progressively contacting said flanged molten edge with said edge or surface of said second object in sufficiently heated condition to cause heat-bonding at the location of said contact, to form a junction between the edge of the first object and the edge of the second object having a radius on each side of the junction equal to at least the thickness of the edge of the first object.
Claim 2
Dependent Claim
157 words
A process for heat bonding an edge of a first thermoplastic resin object to an edge or surface of a second thermoplastic resin object, comprising advancing said first object along a path with its edge in contact with a heated release surface moving therewith to melt its edge, said first object being under compression against said release surface whereby said molten edge forms into a flange thereagainst, progressively removing the said first object and thereby the molten edge in the form of a flange from said release surface, and progressively contacting said flanged molten edge with said edge or surface of said second object in sufficiently heated condition to cause heat-bonding at the location of said contact, to form a junction between the edge of the first object and the edge of the second object having a radius on each side of the junction equal to at least the thickness of the edge of the first object.
Claim 3
Dependent Claim
47 words
The process of claim 1 wherein said first object is a ribbed structure comprising a film and a plurality of ribs integrally molded therewith extending from a surface of said film and the tops of said ribs form the edge melting in contact with said release surface.
Claim 4
Dependent Claim
34 words
The process of claim 2 wherein said path and release surface is curved and the compression of said ribbed structure is obtained by maintaining said ribbed structure under tension while advanced along said path.
Claim 5
Dependent Claim
30 words
The process of claim 2 wherein said second object is in the form of a film and it is a surface thereof that contacts the molten tops of said ribs.
Claim 6
Dependent Claim
62 words
The process of claim 1 wherein said first and second objects are one, in the form of a sheet, and the opposing edges of said sheet in the direction of advancement thereof are each in contact with a heated release surface, and the contacting step consists of bringing the resultant molten edges of said sheet together to form a tubular shape therefrom.