Abstract: A method of continuously forming an integrally molded structure in a multiaxis rotational molding operation including the steps of rotating a multimold section mold assembly about at least three axes. A first freshly formed polymerizable mixture is flowed over surfaces of an enclosed mold cavity within the multisection assembly. Flowing of the first mixture over the cavity surfaces and formation of a first resin therefrom is monitored through optical fibers extending through the mold sections. Second and third freshly formed polymerizable mixtures are flowed over resin formed within the mold cavity. Flowing of the second and third mixtures and formation of resins therefrom are monitored through optical fibers extending through the mold sections. The rotation of the multisection mold assembly is continued throughout the modling operation. Each axis rotation of the multisection mold assembly is monitored individually.

Abstract: Mobile structural unit molding and assembling apparatus includes a support portion, a raw material supplying portion, a molding portion, a unit transferring portion and a control portion. The support portion includes at least one base section with a wheeled carriage. The raw material supplying portion includes a plurality of reservoirs disposed on the base section. The molding portion includes at least one rotatable mold assembly disposed on the base section including at least two separable mold sections. A mixing chamber adjacent the mold assembly connects with raw material reservoirs through independent conduits. The unit transferring portion includes a tiltable unit positioning assembly selectively movable with respect to the molding portion. The control portion includes a programmable memory, a coordinator, sensors, actuators, a unit orienter and circuitry therefor.

Abstract: Multiaxis rotational molding apparatus includes a raw material supplying portion including a plurality of reservoirs connected independently with a mixing portion through conduits. A supporting portion includes a plurality of frame members disposed between upstanding end sections and rotatably supported thereon. A molding portion rotatably supported within the frame members includes at least one rotatable mold assembly with at least two separable mold sections. The mold sections include at least two optical fiber elements extending through the mold sections with one end of each optical fiber element terminating at a mold cavity forming surface of a mold section and an opposite end of each optical fiber element terminating at a remote second surface thereof. A signal generator disposed adjacent a remote surface end of one optical fiber element and a signal sensor disposed adjacent a remote surface end of another optical fiber element.

Abstract: Mobile structural unit molding and assembling apparatus includes a support portion, a raw material supplying portion, a molding portion, a unit transferring portion and a control portion. The support portion includes at least one base section with a wheeled carriage. The raw material supplying portion includes a plurality of reservoirs disposed on the base section. The molding portion includes at least one rotatable mold assembly disposed on the base section including at least two separable mold sections. A mixing chamber adjacent the mold assembly connects with raw material reservoirs through independent conduits. The unit transferring portion includes a tiltable unit positioning assembly selectively movable with respect to the molding portion. The control portion includes a programmable memory, a coordinator, sensors, actuators, a unit orienter and circuitry therefor.

Abstract: Mobile continuous tubular structure forming and placing apparatus includes a support portion, a row material supplying portion, a matrix forming portion, a tubular structure forming portion and a control portion. The raw material supplying portion includes a plurality of reservoirs connected independently with the matrix forming portion through conduits. The tubular structure forming portion includes a frame section and an arcuate blanket support associated with the frame section. A blanket transport is disposed adjacent the arcuate blanket support and aligned therewith, the blanket transport being movable from one end of the arcuate blanket support to an opposite end thereof. A plurality of spaced movable finger members are disposed along each longitudinal edge of the arcuate blanket support with interconnectors joining adjacent finger members.

Abstract: A method of continuously forming an extended length of a unitary structure includes the following steps. A supply of a porous flexible blanket is provided. A high viscosity flowable solidifiable mixture is continuously flowed simultaneously into an entire continuously moving width of the porous flexible blanket. Pressure is applied against the treated blanket to form a uniform matrix therewith. The rate of advance of the blanket is monitored. The rate of advance is coordinated with the flow rate of the mixture into the blanket and with the pressure applied thereto. A substantially flat non-porous flexible envelope is positioned along the length of the treated blanket. The envelope/blanket combination is positioned along a desired path. A pressurized gas is introduced into the envelope. The envelope is inflated to move the treated blanket into a final configuration. The non-porous envelope is maintained in an inflated state until the treated blanket is set in the final configuration.

Abstract: Multi-axis rotational polymeric mixture distributing apparatus includes a raw material supplying portion, a supporting portion, a raw material mixing portion, a polymeric mixture distributing portion, a polymeric mixture accepting portion and a control portion. The raw material supplying portion includes a plurality of reservoirs, each connected independently with the mixing portion. The supporting portion includes a plurality of driven frame members each with a large open central area being disposed between parallel spaced upstanding end sections and rotatably supported thereon, each being progressively smaller in size than the next larger frame member and disposed within the open central area thereof. Alternate frame members are rotatable about aligned axes with frame members therebetween rotatable about axes generally perpendicular thereto. The smallest frame member includes rotatable holding sections.

Abstract: An integrally molded plastic structural unit includes spaced support members joined by a web section disposed therebetween, each of the support members including spaced face sections and an intermediate section therebetween. Each face section includes a stressed hard outer skin. The intermediate section includes a peripheral frame section of high density. The web section includes high density connector members extending between adjoining face sections of the spaced support members. Each of the support members includes mateable sections along at least two edges thereof, with each of the mateable sections including at least five alternating raised and recessed areas forming an asymmetrical pattern along the length of each mateable section. The pattern is the same or a reverse pattern thereof along each mateable section of the same unit and of adjacent units with which it will be assembled.

Abstract: Rotational molding apparatus includes a chemical supplying portion, a chemical mixing portion, a mold portion, a mold supporting portion, a mixture delivery portion and a control portion. The chemical mixing portion includes a tubular member disposed in a substantially horizontal orientation with a plurality of spaced angled deflector sections. The mold portion includes a pair of spacially connected substantially parallel frame sections. The mold supporting portion includes spaced upstanding sections with rotating clamping members selectively engageable with opposite edges of the mold portion. The mixture delivery portion includes a translatable elongated hollow probe member that is selectively connected with the tubular member.

Abstract: A molded structural panel with substantially parallel major surfaces includes integrally formed thin thermosetting resin high density outer sections. Less dense thermosetting resin foam intermediate sections extend inwardly from the outer sections with the density of the intermediate sections decreasing substantially uniformly with increased spacing from the outer sections. A thin thermosetting resin high density central section is located between the intermediate sections. The high density outer sections are in a stressed state from the pressure of the foam intermediate sections thereon.