Abstract: A method for manufacturing a mold component having a conformal thermal management system comprises forming a first mold segment and a second mold segment, each comprising a surface having a profile defined by the surface. A channel pattern is disposed beneath the profile defined by the surface in at least one of the first mold segment and second mold segment. The first mold segment and second mold segment are aligned to form a network of channels. The first mold segment and second mold segment are joined together to form the mold component.

Abstract: In one embodiment, composite pallet comprises: an upper deck, an upper frame member supporting the upper deck, a plurality of foot members disposed in physical contact with the upper frame member, and a lower frame member disposed in physical contact with the plurality of foot members. The upper deck comprises a first half, a second half disposed in communication with a major face of the first half, and a support material disposed between the first half and the second half.

Abstract: In one embodiment, a pallet substructure comprises: a reinforcement structure, a foot member, and a gusset disposed in mechanical communication with the reinforcement structure and the foot member.

Abstract: A pallet includes an upper deck, a support material disposed within the upper deck, an upper frame member supporting the upper deck, a plurality of foot members disposed on the upper frame member, and a lower frame member disposed on the plurality of foot members. The upper deck includes a first half and a second half disposed in communication with a major face of the first half. Numerous variations in which the pallet is collapsible or includes reinforcement members are within the scope of the pallet disclosed.

Abstract: A method for manufacturing a molded article comprises injecting a quantity of molding material sufficient for the preparation of the molded article into a cavity of a mold, injecting a first portion of fluid into the mold cavity, creating a gas channel within the molding material, and forming the molded article within the mold cavity. At least a portion of the first portion of fluid is exhausted through a gas port, a second portion of fluid is injected into the mold material, and the molded article is cooled within the mold cavity to a temperature beneath a softening point of the molding material.

Abstract: In a system for dispersing stormwaters beneath the earth surface, a pair of arch shaped corrugated molded plastic chambers lie parallel each to the other upon a bed of gravel and are covered with soil. A bridge cover spans the space between the sidewalls of the adjacent chambers, to keep soil above from entering. Abutting base flanges establish the chamber spacing which fits the bridge cover and also protect the gravel at the bottom of the space from erosion. Stormwater is delivered to the space, to then flow through sidewall perforations into the chambers' interiors where it is stored and gradually dispersed into the earth. Debris settles in the pocket at the bottom of the space and is removed by a perforated pipe lying in the space. Chambers have high aspect ratios, of 0.8 to 1 or more, and steep sidewall angles, of less than 15 degrees.

Abstract: Large leaching chambers having hollow ribs are formed by gas assisted injection molding. The ribs have stepped cross sections with hollow bases and narrower solid upper parts. When the chamber wall is corrugated, as characterizes a typical arch shape cross section leaching conduit, hollow ribs on opposing sides of the wall are positioned to connect to each by means of holes in the undulating walls. Hollow ribs are narrowed along their length and where they interconnect, alleviating problems distortion and shrinkage problems. And, the chamber wall which surrounds the injection molding sprue is thinner than the typical wall, to avoid hollowing there.

Abstract: Improvements in articles, made by gas assisted injection molding of polyethylene and other materials, such as large arch shaped subsurface leaching conduits, and the processes by which they are made, are disclosed. The improvements involve control of which portions are hollow and which are solid, and include a stepped rib, where the thinner upper rib portion is solid and the wider base is hollow; articles having corrugated surfaces strengthened by ribs on both sides, where the hollows of the opposing side ribs are connected through holes in the undulating walls; articles having ribs which are narrowed where they are solid, compared to their width where they are hollow; and, articles having thinned wall regions surrounding sprues, to avoid undesired hollowing during injection molding.