Process for thermoforming plastic doors

A process for thermoforming a refrigerator door in a molding apparatus using inner and outer plastic sheets, said inner sheet forming the interior door surface and said outer sheet forming the exterior door surface, said molding apparatus includes a means for transporting the sheets, a preheated, interior plug assist mold mounted on means for moving said mold in and out of the work area, said plug assist mold is made with a low heat transfer material, a interior upper male mold containing peripheral resistance wire, a exterior lower female mold containing peripheral resistance wire;

• said interior upper male mold being movably mounted on guide bars;
• said exterior female mold has a flat surface and a raised outer peripheral portion;
• each of said plug assist mold and said interior male mold contain raised peripheral portions and narrow ribs extending outwardly;
• said process comprises the steps of:
• preheating said inner and said outer sheets,
• positioning said outer sheet across said exterior lower female mold,
• positioning said inner sheet across said interior plug assist mold,
• pulling a full vacuum on said outer sheet and pulling a partial vacuum on said inner sheet, said partial vacuum on said inner sheet being sufficient to only partially draw said inner sheet over said narrow ribs of said interior plug assist mold,
• positioning said interior plug assist mold directly beneath said interior upper male mold,
• pulling a full vacuum in said upper male mold, thereby transferring said inner sheet to said interior upper male mold,
• moving said plug assist mold away from the work area,
• joining said inner and said outer formed sheets at the raised peripheral portions and fusing said sheets only at said raised peripheral portions to form a continuous closed chamber between said inner and said outer sheets.