Importance

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Abstract

A thermoplastic composite material is formed from a fabric, preferably woven, impregnated and preferably covered with a thermoplastic material (e.g. acrylic) constituting a monomer solvent and polymer mixture preferably in an approximately 2:1 ratio. The monomer changes the polymer viscosity to wet the fabric. The mixture contains small amounts of an initiator (e.g. benzoyl peroxide) for promoting the monomer polymerization and an inhibitor (e.g. hydroquinone) for preventing premature curing. Plastic sheets on the thermoplastic composite material inhibit the curing. An activator (e.g. tertiary amine) preferably applied to the material surface initiates the material curing at ambient temperatures when the plastic sheets are removed. To reproduce an article from a three-dimensional mold, the mold is disposed on a platform. After removing the plastic sheets, the thermoplastic composite material is disposed on the mold. A shroud (e.g. elastic sheet) disposed over the composite material is sealingly attached to the platform. A vacuum produced at ambient temperatures through the platform collapses the shroud against the composite material which in turn collapses against a male mold and cures as it collapses. A female mold having the male mold shape and disposable over the composite material shapes the composite material after such material has been collapsed against the male mold. Articles of complex or highly contoured shape (e.g. a base portion of a boot for ice skates or in-line roller skates or a helmet shell) may thus be formed.

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First Claim