Abstract: A solid molded polymer composite beam is described that includes at least a first flange; a second flange; at least one web extending between the two flanges wherein the first and second flanges are configured normal to the at least one web; the first flange and the second flange each contains an in-molded rigid insert in the plane of the flanges normal to the at least one web. The method of manufacture and insertion of the in-molded rigid inserts is also described.

Abstract: Composite polymeric articles significantly larger than the size of a compression molding press are produced by providing a plurality of expandable pillows interposed between an upper plate and the upper exterior surface of an outside the press upper mold. The upper plate has a plurality of downwardly extending paired vertical arms attached to opposite sides of the upper plate. Each vertical arm has a lower portion having a eyelet (or aperture), and each pair of vertical arms together forms an aligned pair of eyelets. When the upper and lower mold portions are pressed together, the eyelets reside below the exterior lower surface of the outside the press lower mold portion. Each eyelet is dimensioned to reversibly receive a horizontal or lateral arm that is deployed below the exterior lower surface of the outside the press lower mold portion.

Abstract: The present invention relates to a method and molding system (1) for forming a molded plastic article by wireless control. The molding system includes a primary controller (12) that is adapted to engage in wireless communications with the carriage controller (45) of one or more self-propelled carriages (15). Each carriage (15) includes a carriage location indicator (62) that determines the location of the carriage, which is transmitted substantially continuously to the carriage controller (45), and then communicated substantially continuously and wirelessly from the carriage controller to the primary controller (12). The primary controller (12) wirelessly communicates position directives (e.g., a polymer introduction station position directive) to each carriage controller (45), which correspondingly provides operational position instructions to each carriage's respective propulsion system (30), so as to re-position at least one carriage.

Abstract: The present invention provides a method and apparatae used to prepare a shaped and molded multilayered article formed from a heated thermoplastic sheet and a first plastic sheet that are driven into melt-bonding contact by a stream of gas. The method involves applying a stream of gas (450) against the first surface (417) of a first plastic sheet (411) so as to drive a second surface (420) of the first plastic sheet against and into contact with the first surface (432) of a heated thermoplastic sheet (423) as the heated thermoplastic sheet is formed (e.g., extends downstream from the sheet slot 426 of a sheet die 429). The second surface of the first plastic sheet is defined by a thermoplastic layer.

Abstract: A system for forming an article from composite polymeric material reinforced with fibers and other additives utilizing an extrusion system to heat and deliver the molten composite polymeric material onto a lower mold body riding on an x-y controlled structure. The combination of the x-y control of a lower mold and a volumetrically controlled extrusion device allow a “near net shape” deposition of molten composite material into the cavities of the lower mold, which is then moved over a conveyance system to a press containing the upper mold half which is used to compress and form the composite material into a final part under moderate pressures.

Abstract: A sheet molding apparatus includes at least one molding surface having a plurality of perforations and an accompanying vacuum mechanism for controllably drawing reduced pressure through the perforations. The sheet molding apparatus includes further at least one sheet retainer with a clamping capability attached to a frame surrounding at least a portion of the perimeter edge of the molding surface. The sheet molding apparatus with the sheet retainer and its clamping capability can be used for rapidly and accurately positioning thermoformable thermoplastic sheets to match the molding surfaces in producing molded articles.

Abstract: A sheet molding apparatus including at least one molding surface with a plurality of perforations, at least one sheet retainer with a plurality of vacuum perforations, and an accompanying vacuum mechanism for controllably drawing reduced pressure through the perforations. The sheet molding apparatus can be used for rapidly and accurately positioning thermoformable thermoplastic sheets to match the molding surfaces in producing molded articles.

Abstract: A system and method for forming an article from thermoplastic material and fiber. The method includes heating thermoplastic material to form a molten thermoplastic material for blending with the fiber. The molten thermoplastic material is blended with the fibers to form a molten composite material having a concentration of fiber by weight. The molten composite material may then be extruded through dynamic dies to deliver discrete controlled material that is gravitated onto a lower portion of a mold. The lower portion of the mold may be moved in space and time while receiving the flow of composite material to deposit a predetermined quantity of molten composite material thereon conforming to mold cavities of the lower and an upper portion of the mold. The upper portion of the mold may be pressed against the predetermined quantity of molten composite material and closing on the lower portion of the mold to form the article.

Abstract: A system and method for forming an article from thermoplastic material and fiber. The method includes heating thermoplastic material to form a molten thermoplastic material for blending with the fiber. The molten thermoplastic material is blended with the fibers to form a molten composite material having a concentration of fiber by weight. The molten composite material may then be extruded through dynamic dies to deliver discrete controlled material that is gravitated onto a lower portion of a mold. The lower portion of the mold may be moved in space and time while receiving the flow of composite material to deposit a predetermined quantity of molten composite material thereon conforming to mold cavities of the lower and an upper portion of the mold. The upper portion of the mold may be pressed against the predetermined quantity of molten composite material and closing on the lower portion of the mold to form the article.

Abstract: A heat exchange panel (1) that includes a lower plate (11) and an upper plate (14) that together define a plurality of channels (51) there-between, which are in fluid communication with a plurality of upper plate extension passages (72), is described. The lower plate (11) includes a plurality of lower plate extensions (20) that extend upwardly from the interior surface (17) of the lower plate. Each channel (51) has at least one lower plate extension (20) extending upwardly therefrom. The upper plate (14) includes a plurality of upwardly extending hollow upper plate extensions (32). The aperture (42) and interior hollow space (48) of each upper plate extension (32) is aligned with and receives an upper portion (69) of a single lower plate extension (20) therein.

Abstract: A load bearing assembly (300, 452) that includes at least one molded plastic panel (1) and/or at least one molded plastic panel assembly (3), a first support (303) and optionally a second support (306), is described. Each panel (1) of the load bearing assembly (300) includes a first external portion (17) and a second external portion (20), each having a plurality of reinforcing structures (49, 79) having sidewalls (52, 82) that define a plurality of external portion recesses (64, 98).

Abstract: The present invention relates to a method of forming a molded article (e.g., 141) from first and second heated and thermoformable thermoplastic sheets (75, 78), which are each respectively formed in situ from first and second thermoplastic compositions (e.g., by means of extrusion). The heated first and second thermoformable sheets are each drawn by reduced pressure into contour matching contact with the interior mold surfaces (14, 32) of separate first and second mold portions (11, 29), so as to form separate first and second profiled thermoplastic sheets (129, 144) within the separate mold portions. The first and second mold portions (11, 29) are positioned towards each other (e.g., together) so as to bring into contact and fuse together contact portions (159, 163) of the first and second profiled thermoplastic sheets (129, 144). Fusion between the contacted contact portions (159, 163) is achieved by means of (e.g.

Abstract: A solar energy collector system includes a solar collector configured to reflect sunlight to a diffused focal point, and a photovoltaic cell assembly carried by the solar collector. The photovoltaic cell assembly includes a collector housing positioned at the diffused focal point to receive the reflected sunlight, and photovoltaic cells within the collector housing to generate electricity based on the reflected sunlight. The collector housing includes a cooling liquid to cool the photovoltaic cells when generating the electricity.

Abstract: The present invention relates to a method and molding system (1) for forming a molded plastic article by wireless control. The molding system includes a primary controller (12) that is adapted to engage in wireless communications with the carriage controller (45) of one or more self-propelled carriages (15). Each carriage (15) includes a carriage location indicator (62) that determines the location of the carriage, which is transmitted substantially continuously to the carriage controller (45), and then communicated substantially continuously and wirelessly from the carriage controller to the primary controller (12). The primary controller (12) wirelessly communicates position directives (e.g., a polymer introduction station position directive) to each carriage controller (45), which correspondingly provides operational position instructions to each carriage's respective propulsion system (30), so as to re-position at least one carriage.

Abstract: A molded panel is provided, which includes a body and a plurality of supporting members. The body includes a generally planar top surface and a bottom surface. The supporting members extend from the bottom surface of the body to define a support structure. The support structure includes a top surface adjacent to the bottom surface of the body, a generally planar bottom surface and at least one edge extending therebetween. The support structure also includes at least one channel extending along a central x-axis of the support structure, and at least one additional channel intersecting the at least one central channel and extending along a y-axis of the support. The y-axis is generally perpendicular to the x-axis. A connection system for the molded panel, systems including the molded panel, and methods related to the molded panel are also described.

Abstract: The method includes providing a mold apparatus (1) that includes, a first mold portion (11) having an interior mold surface (14) having a plurality of perforations (26) and a perimeter edge (17). The mold apparatus (11) further includes at least one tubular sheet retainer (35) having an exterior surface (38) having a plurality of perforations (41) and a longitudinal axis (44) that is oriented along at least a portion of the perimeter edge (17) of the first mold portion (11). Each tubular sheet retainer (35) is reversibly and controllably: (i) positionable along an x-, y- and/or z-axis relative to the perimeter edge (17); and (ii) rotatable around its longitudinal axis (44), toward and/or away from the perimeter edge (17). A heated thermoplastic sheet (95) is formed and contacted (while at a thermoformable temperature) with the interior surface (14) of the first mold portion (11) and the exterior surfaces (38) of the tubular sheet retainers (35).

Abstract: A solar dish collector system includes a solar dish collector panel for reflecting sunlight, and a conduit adjacent the solar dish collector panel. The conduit includes a supply tube to provide fluid to be heated by the reflected sunlight, and a return tube to return the heated fluid. A collector encloses open ends of the supply and return tubes, and is positioned to receive the reflected sunlight from the solar dish collector panel. The fluid from the supply tube at least partially fills the collector and is heated by the reflected sunlight while circulating therein. The heated fluid is then returned via the return tube.

Abstract: A method of forming a molded plastic article with a second surface with molded extensions, and a first surface that is substantially free of sink mark defects. The method involves forming, from a first plastic material, a first molded section with at least one molded extension extending from the second surface. The molded extension is formed in a mold recess with a reversibly positionable slide. After formation of the first molded section, the slide is retracted to a second slide position thus forming within the molded extension a retainer cavity that is in fluid communication with an aperture in the first surface of the first molded section. A second plastic material is introduced into the mold over the first molded section, and a portion thereof passes through the aperture and into the retainer cavity, thereby forming a second molded section that is continuous with each retainer.

Abstract: A method of forming a molded plastic article with a second surface with molded extensions, and a first surface that is substantially free of sink mark defects. The method involves forming, from a first plastic material, a first molded section with at least one molded extension extending from the second surface. The molded extension is formed in a mold recess with a reversibly positionable slide. After formation of the first molded section, the slide is retracted to a second slide position thus forming within the molded extension a retainer cavity that is in fluid communication with an aperture in the first surface of the first molded section. A second plastic material is introduced into the mold over the first molded section, and a portion thereof passes through the aperture and into the retainer cavity, thereby forming a second molded section that is continuous with each retainer.

Abstract: A method of preparing a molded article, and more particularly to a method of forming a shaped thermoplastic sheet. The method includes providing a mold apparatus that includes a first mold portion with a contoured and perforated interior mold surface, and a perimeter edge. The mold apparatus also includes a frame that surrounds at least a portion of the perimeter edge of the first mold portion. At least one sheet retainer resides on the upper surface of the frame. Each sheet retainer includes a clamp portion that faces towards the perimeter edge of the first mold portion, and which includes a reversibly closeable clamp member which defines in part a clamp interior. Each sheet retainer is independently, reversibly and laterally attached to the upper surface of the frame, such that each clamp portion is reversibly and laterally positionable relative to the perimeter edge of the first mold portion.