Abstract: A method of forming a shaped thermoplastic sheet includes providing a mold apparatus that includes, a first mold portion having an interior mold surface having a plurality of perforations and a perimeter edge. The mold apparatus further includes at least one sheet retainer having an upper surface having a plurality of perforations and a longitudinal axis that is oriented along at least a portion of the perimeter edge of the first mold portion. Each sheet retainer is reversibly and controllably: positionable along an x-, y- and/or z-axis relative to the perimeter edge; and rotatable around its longitudinal axis, toward and/or away from the perimeter edge. A heated thermoplastic sheet is formed and contacted (while at a thermoformable temperature) with the interior surface of the first mold portion and the exterior surfaces of the tubular sheet retainers. Reduced pressure is drawn through the perforations of the sheet retainers thereby retaining a portion of the heated thermoplastic sheet thereon.

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: 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 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: 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). Each sheet retainer (148) is independently, reversibly and laterally attached to the upper surface (38) of the frame (35), such that each clamp portion (151) is reversibly and laterally positionable relative to the perimeter edge (17) of the first mold portion (11).

Abstract: In accordance with the present invention, there is provided a method of forming a molded plastic article (2) having a second surface (56) with molded extensions (59), e.g., structural supports, such as ribs, extending therefrom, and a first surface (69) that is substantially free of sink mark defects. The method involves forming, from a first plastic material, a first molded section (50) having at least one molded extension (59) extending from the second surface (56) thereof. The molded extension (59) is formed in a mold recess (23) having a reversibly positionable slide (14) therein. After formation of the first molded section (50), the slide (14) is retracted to a second slide position (B) thus forming within the molded extension a retainer cavity (74) that is in fluid communication with an aperture (71) in the first surface (53) of the first molded section (50).

Abstract: A solar energy collector system includes a base, and a parabolic trough collector carried by the base for reflecting sunlight to a longitudinal focal line. The parabolic trough collector includes a center section horizontally positioned with respect to ground, and opposing end sections adjacent the center section. Each end section is angled towards the ground. A conduit is positioned along the longitudinal focal line to receive the reflected sunlight. The conduit circulates a heat transfer liquid therethrough to be heated by the reflected sunlight.

Abstract: A molded plastic panel and a molded plastic panel assembly including at least two molded panels are described. Each panel includes a center portion (14) that is positioned between and which is continuous with a first external portion (17) and a second external portion (20). The center portion (14) has a plurality of plastic center reinforcing structures (31) that define a plurality of center portion apertures (34). Each of the first and second external portions include reinforcing structures (49, 79) having sidewalls (52, 82) having interior surfaces (55, 85) that define a plurality of external portion apertures (61, 94). The exterior surfaces (58, 88) of sidewalls of neighboring reinforcing structures together define a plurality of external portion recesses (64, 98) that are dimensioned to receive extensions from a separate article, thereby forming interlocks there-between. With the panel assembly (3) of the present invention, at least two molded panels (e.g.

Abstract: A solar energy collector apparatus includes a solar collector panel having a parabolic shape, and a base comprising a pair of spaced apart support frames. Each support frame has a parabolic shape corresponding to the parabolic shape of the solar collector panel. Spaced apart rollers are positioned along an upper surface of each support frame to support the solar collector panel. A drive mechanism is coupled to the solar collector panel for rotation thereof. The solar collector panel includes a pair of spaced apart guide channels on an underside thereof for contacting the spaced apart rollers to insure that the solar collector panel rotates squarely with respect to the base.

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). 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: 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: 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 thermoplastic molding process uses the thermoplastic molding apparatus to mold a part of variable thickness from a slab of material heated during extrusion. The thermoplastic molding system includes a thermoplastic extrusion die for the extrusion of a thermoplastic slab. The extrusion die has adjustable die gate members for varying the thickness of the extruded material in different parts of the extruded slab. A plurality of molds are mounted to the platform to feed one mold into a loading position while a second mold is in a release position.