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 method of forming a molded plastic article having at least one molded extension extending from a second surface, and a first surface that is substantially free of sink mark defects. The method involves providing a mold (that includes a first mold portion with a recess. Part of the base of the recess is defined by the upper surface of a part ejector. A first plastic material is introduced into the recess to form a molded extension. After at least partial solidification of the molded extension, the part ejector is positioned to push the upper surface and upper portion of the molded extension out of the recess while a lower portion of the molded extension remains within the recess. A second plastic material is introduced into the mold so as to form a molded body in which the upper surface and upper portion of the molded extension are immersed and embedded. As a result the first surface of the molded body is substantially free of sink mark defects opposite the molded extension.

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: In accordance with the present invention, there is provided a method of forming a molded plastic article having at least one molded extension extending from a second surface thereof, and a first surface that is substantially free of sink mark defects. The method involves providing a mold (1) that includes a first mold portion (11) having a recess (23) therein. At least a portion of the base (29) of the recess (23) is defined by the upper surface (44) of a part ejector (14). A first plastic material is introduced into the recess (23) so as to form a molded extension (47). After at least partial solidification of the molded extension (47), the part ejector (14) is positioned so as to push the upper surface (50) and upper portion (53) of the molded extension out of the recess (23), while a lower portion (56) of the molded extension remains within the recess.

Abstract: An improved method for forming a hollow core structural member, such as an automotive bumper beam, from moldable plastic sheets, such as fiberglass reinforced plastic sheets, by providing a press having a desired shape on the opposing members of the press, placing opposed sheets in the press with a layer of frozen, meltable material, such as ice, in place between them, forming the sheets into the desired article configuration in the press, removing the formed member from the press, then melting and removing the meltable material from the interior of the formed member.