Abstract: Apparatuses and methods for bonding together two or more layers of oriented polymer material or secondary material to form a rigid member. Two or more layers of material are initially restrained along an orientation axis to prevent contraction and loss of orientation. Then, the contact surfaces of each layer of material are heated to a temperature above the melting point for each respective material. Next, the heated contact surfaces are merged together, and pressure is applied to the merged contact surfaces to combine the layers. Once combined, the layers are cooled, and a rigid unitary member is formed.

Abstract: Apparatuses and methods for bonding together two or more layers of oriented polymer material or secondary material to form a rigid member. Two or more layers of material are initially restrained along an orientation axis to prevent contraction and loss of orientation. Then, the contact surfaces of each layer of material are heated to a temperature above the melting point for each respective material. Next, the heated contact surfaces are merged together, and pressure is applied to the merged contact surfaces to combine the layers. Once combined, the layers are cooled, and a rigid unitary member is formed.

Abstract: A molding process in which a material with an open cell, porous structure 10 is placed, aligned or supported inside a suitable enclosed holding device. Another molding material 20 is subsequently injected into the said holding device while gas and/or pressure is sequentially applied to the said holding device, causing a synergistic interaction and joining between the said materials to take place. During the processing phase, gas is evenly dispersed throughout the porous core, effectively equalizing cavity pressure and permitting an even flow pattern to exist, encapsulating or sandwiching the said porous structure, thus forming a composite material with physical properties which are substantially greater than the individual components.