Abstract: An enclosed structure (1) that includes a base perimeter structure (11), an exterior wall structure (17) and a roof structure (23), is described. The base perimeter structure (11) includes a plurality of base plates (14) that each include a base (29), an interior flange (32) and an exterior flange (35) each extending upwardly from the base (29) and together defining a channel (41). Base (29) of each base plate (14) includes an exterior base portion (56) having an upper exterior surface (59) that slopes downwardly and outwardly from the exterior flange (35). The base plates are arranged such that the channels (41) thereof are aligned and together define a base perimeter channel (74). The exterior wall structure (17) includes a plurality of sidewall panels (20) that each includes first and second sidewall tabs (179, 182) extending outwardly from sidewall edges thereof (167, 170).

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 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). Each support (303, 306) has a plurality of extensions (318, 339) that are received within the external portion recesses (64, 98) of the panel with which they are aligned. Receipt of the support extensions (318, 339) within the external portion recesses (64, 98) of the panel serves to attach the molded panel and the support(s) together, thereby forming the load bearing assembly (300).

Abstract: The present invention relates to a molded pile (e.g., 17) that includes a unitary elongated body (52) and an elongated tube (142) residing longitudinally within the elongated body (52). The elongated body (52) includes first (151) and second (154) exterior elongated plates that are spaced apart and opposed to each other. The elongated body (52) also includes a plurality of internal ribs (157) interposed between and being continuous with the first (151) and second (154) exterior elongated plates. The internal ribs (157) together define a plurality of apertures (67) and an elongated passage (160) that extends the length of the elongated body (52). The elongated tube (142) resides within the elongated passage (160), and provides fluid communication between upper (145) and lower (148) ends of the elongated body. Passage of a high pressure fluid (e.g., water and/or air) through elongated tube 142 results in fluidization of a penetrable material (e.g.

Abstract: The present invention relates to a method of preparing a molded article, and more particularly to a method of forming a shaped thermoplastic sheet (e.g., a fluid management structure). The method includes providing a mold apparatus (1) that includes a first mold portion (11) having a contoured and perforated interior mold surface (14), and a perimeter edge (17). The mold apparatus also includes a frame (35) that surrounds at least a portion of the perimeter edge (17) of the first mold portion (11). At least one sheet retainer (148) resides on the upper surface (38) of the frame (35). Each sheet retainer (148) includes a clamp portion (151) that faces towards (or in the direction of) the perimeter edge (17) of the first mold portion (11), and which includes a reversibly closeable clamp member (154) which defines in part a clamp interior (157).

Abstract: The present invention relates to a molded pile (e.g., 17) that includes a unitary elongated body (52) and an elongated tube (142) residing longitudinally within the elongated body (52). The elongated body (52) includes first (151) and second (154) exterior elongated plates that are spaced apart and opposed to each other. The elongated body (52) also includes a plurality of internal ribs (157) interposed between and being continuous with the first (151) and second (154) exterior elongated plates. The internal ribs (157) together define a plurality of apertures (67) and an elongated passage (160) that extends the length of the elongated body (52). The elongated tube (142) resides within the elongated passage (160), and provides fluid communication between upper (145) and lower (148) ends of the elongated body. Passage of a high pressure fluid (e.g., water and/or air) through elongated tube 142 results in fluidization of a penetrable material (e.g.

Abstract: A support structure (1) that includes a support panel (11), at least one pile (14) having associated therewith at least one bracket (17) and at least one mounting strap (20), is described. Each bracket (17) includes a lower portion (70), at least one extension (91, 92) extending upward from the lower portion (70), and a retainer (85) extending outward from a first surface (73) of the lower portion (70). The retainer (85) of the bracket (17) is received within an aperture (67) of an apertured sidewall (64, 215, 218) of the pile (14). At least one mounting strap (20, 23) maintains: the first surface (73) of the lower portion (70) of the bracket (17) in abutting relationship with the apertured sidewall (64) of the pile; and the retainer (85) within the aperture (67) thereof. A first surface (94) of the extension (91, 92) of the bracket (17) and the apertured sidewall (64) of the pile (14) together define a vertical slot (112) having an open top (115) and a closed bottom (118).

Abstract: A method of forming a shaped thermoplastic sheet is described. 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 sheet retainer (35) having an upper 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 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 method of forming a shaped thermoplastic sheet is described. 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 molded support beam (1, 2, 3) that includes an elongated lower portion (11) an elongated upper portion (14) and at least one elongated flange (17, 18) extending upwardly from the elongated upper portion, is described. The elongated lower portion (11) includes at least three separate downwardly extending supports (e.g., 29, 32, 35) which together define at least two open-bottomed transverse openings (e.g., 41, 44), at least one of which being an arched open-bottomed transverse opening (e.g., 219, 234, 249). The elongated upper portion (14) includes a longitudinal passage (68), and a ledge (92) that extends horizontally outward from a second vertical side (56) thereof. An elongated hollow support tube (74) resides within the longitudinal passage (68) of the elongated upper portion (14).

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.