Abstract: An improved modular building panel and system for building construction is disclosed. The improved modular building panel comprises a novel honeycomb or lattice core comprising multiple layers of corrugated, preferably metal, components mechanically connected by any means known in the art, but which may be chemical bonding. External cladding layers comprising a novel cement mix comprising, in a preferred embodiment, Portland cement, silica sand, perlite, glass beads, and water, in combination with the honeycomb structure, provide a lightweight, highly durable, low-cost, projectile resistant, highly insulating, water, mold and mildew resistant, wind resistant novel modular wall system which is adapted for use in commercial, residential, and other construction and which provides superior security to the user. The modular building panel and system of the invention may be utilized for walls, roofs, floors, bridges, or other structures.

Abstract: An improved modular building panel and system for building construction is disclosed. The improved modular building panel comprises a novel honeycomb or lattice core comprising multiple layers of corrugated, preferably metal, components mechanically connected by any means known in the art, but which may be chemical bonding. External cladding layers comprising a novel cement mix comprising, in a preferred embodiment, Portland cement, silica sand, perlite, glass beads, and water, in combination with the honeycomb structure, provide a lightweight, highly durable, low-cost, projectile resistant, highly insulating, water, mold and mildew resistant, wind resistant novel modular wall system which is adapted for use in commercial, residential, and other construction and which provides superior security to the user. The modular building panel and system of the invention may be utilized for walls, roofs, floors, bridges, or other structures.

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 sheet molding apparatus includes at least one molding surface having a plurality of perforations and an accompanying vacuum mechanism for controllably drawing reduced pressure through the perforations. The sheet molding apparatus includes further at least one sheet retainer with a clamping capability attached to a frame surrounding at least a portion of the perimeter edge of the molding surface. The sheet molding apparatus with the sheet retainer and its clamping capability can be used for rapidly and accurately positioning thermoformable thermoplastic sheets to match the molding surfaces in producing molded articles.

Abstract: A sheet molding apparatus including at least one molding surface with a plurality of perforations, at least one sheet retainer with a plurality of vacuum perforations, and an accompanying vacuum mechanism for controllably drawing reduced pressure through the perforations. The sheet molding apparatus can be used for rapidly and accurately positioning thermoformable thermoplastic sheets to match the molding surfaces in producing molded articles.

Abstract: 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 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 preparing a molded article, and more particularly to a method of forming a shaped thermoplastic sheet. The method includes providing a mold apparatus that includes a first mold portion with a contoured and perforated interior mold surface, and a perimeter edge. The mold apparatus also includes a frame that surrounds at least a portion of the perimeter edge of the first mold portion. At least one sheet retainer resides on the upper surface of the frame. Each sheet retainer includes a clamp portion that faces towards the perimeter edge of the first mold portion, and which includes a reversibly closeable clamp member which defines in part a clamp interior. Each sheet retainer is independently, reversibly and laterally attached to the upper surface of the frame, such that each clamp portion is reversibly and laterally positionable relative to the perimeter edge of the first mold portion.

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: 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: 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 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: 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 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 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).