Abstract: A process is disclosed for producing reinforced twin-sheet thermoformed articles comprising the steps of heating first and second sheets of thermoplastic material; forming the sheets in molds; heating a reinforcing insert of thermoplastic material; placing the heated insert on the first sheet in its mold at the location to be reinforced; pressing the second sheet into contact with the heated first sheet and the heated insert to form the insert between the sheets so that a fusion of the thermoplastic sheets and the insert takes place to produce a reinforced section of the article having a desired shape and thickness. Alternative processes are disclosed wherein a heated quantity of thermoplastic liquid material is extruded or injected between the first and second sheets within the first and second molds either by inserting the liquid material before the molds are closed or by injecting it through one of the molds.

Abstract: A process is disclosed for producing reinforced twin-sheet thermoformed articles comprising the steps of heating first and second sheets of thermoplastic material; forming the sheets in molds; heating a reinforcing insert of thermoplastic material; placing the heated insert on the first sheet in its mold at the location to be reinforced; pressing the second sheet into contact with the heated first sheet and the heated insert to form the insert between the sheets so that a fusion of the thermoplastic sheets and the insert takes place to produce a reinforced section of the article having a desired shape and thickness. Alternative processes are disclosed wherein a heated quantity of thermoplastic liquid material is extruded or injected between the first and second sheets within the first and second molds either by inserting the liquid material before the molds are closed or by injecting it through one of the molds.

Abstract: A process is disclosed for producing reinforced twin-sheet thermoformed articles comprising the steps of heating first and second sheets of thermoplastic material; forming the sheets in molds; heating a reinforcing insert of thermoplastic material; placing the heated insert on the first sheet in its mold at the location to be reinforced; pressing tile second sheet into contact with the heated first sheet and the heated insert to form the insert between tile sheets so that a fusion of the thermoplastic sheets and tile insert takes place to produce a reinforced section of the article having a desired shape and thickness. Alternative processes are disclosed wherein a heated quantity of thermoplastic liquid material is extruded or injected between the first and second sheets within the first and second molds either by inserting the liquid material before the molds are closed or by injecting it through one of the molds.

Abstract: A plastic pallet has a twin sheet thermoformed upper deck reinforced with a tubular metal substrate. Injection molded plastic octagonal posts have support member walls which are positioned beneath reinforced portions of the top deck. The posts also have a sleeve with a central bolt hole which is parallel to the support member walls. A twin sheet thermoformed lower deck is spaced from the upper deck by the posts and receives the posts in recessed pockets. Plastic bolts are inserted through the top deck, each post, and the bottom deck and are held in place by plastic T-nuts. A sawtooth parting line in the twin-sheet thermoforming molds provide accurate alignment and molding of the pallet parts.

Abstract: A wooden upper deck is connected by two types of plastic spacer blocks to a wooden lower deck. The upper deck may be a conventional deck composed of stringers and slats or it may be a twin sheet thermoformed plastic deck. The lower deck is composed of stringers which underlie the plastic spacers and tie boards which abut the ends of the stringers. Connector spacer blocks serve both to join the upper deck to the lower deck and to connect the stringer boards to the tie boards. The stringers and tie boards are held in fixed relation by bolts which join the upper and lower decks passing through sockets in the spacer blocks. The stringers and the tie boards are bolted to the spacer blocks and are thus joined. The joint between the stringers and the tie boards may be strengthened by means of a metal link overlying the stringers and tie boards and linking the bolts together.

Abstract: A plastic pallet has a twin sheet thermoformed upper deck reinforced with a tubular metal substrate. Injection molded plastic octagonal posts have support member walls which are positioned beneath reinforced portions of the top deck. The posts also have a sleeve with a central bolt hole which is parallel to the support member walls. A twin sheet thermoformed lower deck is spaced from the upper deck by the posts and receives the posts in recessed pockets. Plastic bolts are inserted through the top deck, each post, and the bottom deck and are held in place by plastic T-nuts. The pallet is sealed against entry of liquid into the interior space of the pallet and may be stored on a flat surface or elevated on a rack.

Abstract: A twin sheet thermoformed pallet upper deck has a reinforcing metal substrate and downwardly protruding detents which engage with a hoisting cable or strap. Notches are formed on the sides of the top deck and restrict the escape of the cable when the pallet is elevated. A twin sheet thermoformed, metal substrate reinforced, lower deck is bolted to the upper deck through injection molded plastic legs which have upper and lower protrusions which fit within semi-circular pockets located on the upper and lower decks. Fasteners extend through metal gusset plates welded to the upper and lower deck substrates to form a rigid and strong pallet.

Abstract: Reinforced twin-sheet thermoformed articles are produced by heating first and second sheets of thermoplastic material; forming the sheets in molds; heating a reinforcing insert of thermoplastic material; placing the heated insert on the first sheet in its mold at the location to be reinforced; pressing the second sheet into contact with the heated first sheet and the heated insert to form the insert between the sheets so that a fusion of the thermoplastic sheets and the insert takes place to produce a reinforced section of the article having a desired shape and thickness. Alternatively, a heated quantity of thermoplastic liquid material may be extruded or injected between the first and second sheets within the first and second molds either by inserting the liquid material before the molds are closed or by injecting it through one of the molds.

Abstract: A plastic pallet has a twin sheet thermoformed upper deck reinforced with a tubular metal substrate. Injection molded plastic octagonal posts have support member walls which are positioned beneath reinforced portions of the top deck. The posts also have a sleeve with a central bolt hole which is parallel to the support member walls. A twin sheet thermoformed lower deck is spaced from the upper deck by the posts and receives the posts in recessed pockets. Plastic bolts are inserted through the top deck, each post, and the bottom deck and are held in place by plastic T-nuts. The pallet is sealed against entry of liquid into the interior space of the pallet and may be stored on a flat surface or elevated on a rack.

Abstract: A twin-sheet thermoformed thermoplastic aquatic biomass containment barrier with reinforced hinges is disclosed having a formed first extended linear thermoplastic sheet member which is fused to a formed second linear extended thermoplastic sheet member of substantially the same dimensions as the first member to form a composite unit member having two ends and air pockets formed between the two sheets to give buoyancy to the segment. Reinforcing thermoplastic inserts are located between the first and second members at each end of the composite member. Each insert has portions defining a central pinhole and is fused to the first and second members to form reinforced hinged sections. The hinged segments may be connected by pins to form a floating aquatic biomass containment barrier cell or a network of cells. Such a network is effective for the growth and harvesting of small aquatic plants such as the duckweed plant.

Abstract: A reinforced twin-sheet thermoformed pallet is disclosed which has a substantially planar load-bearing member which is formed from an upper sheet of thermoplastic material and a lower sheet of thermoplastic material located generally in fixed parallel relationship to each other. A plurality of concave depressions in the load-bearing member form feet which depend from the load-bearing member. Each foot is formed as a downwardly depending portion of each of the two sheets of material joined together. Each foot has an inner foot floor formed from the upper sheet and an outer foot floor formed from the lower sheet. A quantity of reinforcing thermoplastic material is located between the inner and outer walls of each foot and is fused to the upper and lower sheets to form an integral foot floor which is substantially parallel to the load-bearing member. The thickness of the foot floor is substantially greater than the combined thicknesses of the upper and lower sheets.