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 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 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 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 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: 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: 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: 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: 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 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 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.

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 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. The thermoplastic extrusion die has a trimmer for cutting the extruded thermoplastic slab from the thermoplastic extrusion die. A plurality of thermoplastic molds, which may be either vacuum or compression molds, are each mounted on a movable platform, such as a rotating platform, for moving one mold at a time into a position to receive a thermoplastic slab being trimmed from the thermoplastic extrusion die. A molded part is formed with a variable thickness from a heated slab of thermoplastic material being fed still heated from the extrusion die. 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.