Abstract: A device having an improved thermal barrier coating (46) and a process for manufacturing the same. A support structure (28) for retaining a ceramic insulating material (46) on a substrate (16) is formed by the deposition of a support structure material through a patterned masking material (14). The support structure can define cells into which the ceramic insulating material is deposited following removal of the masking material. The masking material may be patterned by known photolithographic techniques (22,24) or by laser etching (48). The support structure (28) may be a composite metal-ceramic material having either discreet layers (30,34) or a graded composition and may be deposited by an electro-desposition process followed by a heat treatment to form a solid state diffusion bond with the substrate.

Abstract: A protective packaging sheet which is particularly suitable for packaging heavy loads such as coils of sheet steel. The packaging sheet is formed from a plastics sheet material having inherently relatively low compressions strength and resistance to impact forces and bending. These mechanical properties are vastly improved in the embossed packaging sheet. At least one of the surfaces of the sheet material is provided with shaped protuberances juxtaposed with adjacent shaped protuberances to provide a gap around each shaped protuberance. The shaped protuberances are arranged in such a way that all straight lines projected onto the surface cut through the shaped protuberances in addition to the gaps.

Abstract: A panel comprising at least one layer of thermoformable plastics material having separate regions of different thickness, is obtained by a method comprising the steps of: extruding of a sheet of plastics material with the addition to the said material of an expansion agent, the extrusion being conducted in conditions such as to avoid expansion of the material or to cause only partial expansion thereof; heating the thus-obtained sheet to a temperature such as to cause post expansion of the material; and thermoforming the sheet in a thermoforming cavity of complementary shape to the desired panel so that the thermoformed panel produced has in the regions of greater thickness an expanded cellular structure where the material has a lower density than the density of the material in the regions of lesser thickness.

Abstract: A three-dimensional deep molded structure made from planar knits or wovens composed of homo-component, bicomponent or multi-component fibers having a fiber diameter of less than 100 microns and nonwovens composed of fibers or filaments of any size. Most suitably, nonwovens with a random fiber orientation distribution and a high degree of crimp with partially oriented fibers are preferred for use in forming the deep molded structure.

Abstract: A disruptive camouflage pattern system to be used for both military and civilian applications. The system includes specialized techniques for printing the camouflage pattern system unto fabric. The system provides camouflage in both the human visible light and the near infrared range. The system depends on macro pattern resulting from a repeat of a micro pattern. The coloring used includes at least four colorings from dyes that in combination produce a percent reflectance value comparable to that of the negative space of the camouflaged subject's surroundings. The system functions by a macro pattern being disruptive of the subject's shape and a micro pattern having sharp edge units of a size capable of blending the subject into its background. The relative lightness values and percentages of total pattern, wet or dry, are sufficient to produce a percent reflectance of acceptable colors, in terms of lightness values unlike current four-color camouflage.

Abstract: A composite panel waffle stiffener has fabric plies pre-cut to a selected pattern and laid on a tool having a waffle configuration. The plies overlap each other to maintain continuity of the structure. The resulting waffle stiffener is then bonded to a panel requiring stiffening. The stiffener is flexible and may be bonded to curved panels. Holes in the stiffener allow access to the volume between the stiffener and the panel for minimizing volume loss within, for example, a wing structure containing fuel and for ventilating air or moisture trapped in the volume.

Abstract: A web is formed from two sheets of polymeric material. An upper sheet includes pockets of any form. A lower sheet is subsequently bonded to the upper sheet which causes the sealing of each of the pockets. A web thus formed may be laminated with a metallic foil or metallized polymeric film. Such a web may also be laminated with a similar web in a face to face relationship so that the pockets interdigitate.

Abstract: An apparatus and method for stiffening a panel provides a composite waffle stiffener and the method for constructing the stiffener. A plurality of fabric plies pre-cut to a selected pattern are laid on a tool having a waffle configuration, the plies overlapping each other to maintain continuity of the structure. The resulting waffle stiffener is then bonded to a panel requiring stiffening. The stiffener is flexible and may be bonded to curved panels. Holes in the stiffener allow access to the volume between the stiffener and the panel for minimizing volume loss within, for example, a wing structure containing fuel and for ventilating air or moisture trapped in the volume.

Abstract: A panel structure for a transport machine is disclosed which is constituted by an integral combination of an outer panel and an inner panel. The inner panel has reinforcing protuberances and recesses, possessing a higher rigidity than the outer panel. The protuberances of the inner panel and a back side of the outer panel are bonded together through insulating layers present on the protuberances.

Abstract: A reflection-reducing film formed by being applied onto the surface of a substrate having light transmitting property, and including a base layer formed on the surface of said substrate and a surface layer formed on the upper side of said base layer, wherein: said base layer has a thickness of from 50 to 200 nm; and said surface layer is formed of a hydrolyzed product of a silane compound represented by the following formula (I), Rn—Si(X)4-n  (I)  wherein R is a substituted or unsubstituted alkyl group or an alkenyl group, X is a hydrolyzable group, and n is a number of 1 or 2, a metal chelate compound and a silica sol, and has a thickness of from 50 to 200 nm. The reflection-reducing film is easily formed on a light-transmitting substrate by applying a multi-layer coating thereon, and exhibits an excellent liquid resistance.

Abstract: A layer structure has at least two material layers with an intermediate or casting layer interposed between adjacent material layers. The intermediate layer includes a casting material and a plurality of elongated elements having different orientations which are extending across each other to form a weave to determine the interspacing between the two material layers before any casting material of the intermediate layer is inserted. The two material layers which are to be joined together may be gradient coils of a tomograph.

Abstract: A substance delivery system has a three dimensional structure with outermost surface features and spaces for containing a substance. The substance has a level below the outermost surface features such that the substance is protected from inadvertent contact with external surfaces. The substance remains protected until the three dimensional structure is sufficiently deformed into a substantially two dimensional structure and the substance is thereby exposed to contact an external surface without compliance of the external surface being necessary. Deforming is preferably achieved by a compression force, wherein the outermost surface features of the three dimensional structure deform in a direction of the compression force.

Abstract: A reflective insulative blanket for use in construction applications, such as curing concrete, thawing frozen ground and other insulative purposes. The blanket comprises at least one moisture-impervious layer attached to an insulative layer. The insulative layer includes a plurality of hollow, insulative elements. The moisture-impervious layer may close the insulative elements and/or the space surrounding the insulative elements, thereby entrapping air to provide the insulative properties of the blanket. The blanket preferably includes two moisture-impervious layers, one attached to each side of the insulative layer. The blanket further includes a reflective layer secured to the outside of at least one of the moisture-impervious layers. The reflective layer reflects thermal energy before it has passed through any portion of the blanket, thereby reducing heat retention within the blanket and improving lateral thermal conduction.

Abstract: An apparatus and method for stiffening a panel provides a composite waffle stiffener and the method for constructing the stiffener. A plurality of fabric plies pre-cut to a selected pattern are laid on a tool having a waffle configuration, the plies overlapping each other to maintain continuity of the structure. The resulting waffle stiffener is then bonded to a panel requiring stiffening. The stiffener is flexible and may be bonded to curved panels. Holes in the stiffener allow access to the volume between the stiffener and the panel for minimizing volume loss within, for example, a wing structure containing fuel and for ventilating air or moisture trapped in the volume.

Abstract: A spacer plate for use in making a hollow floor has a plurality of truncated cone-shaped spacer elements extending from one side of the plate, and distributed in a row wise and column wise arrangement, for supporting the spacer plate from an underfloor, and also formed in the spacer plate are grooves formed in the same side of the plate as the spacer elements for holding a pipe conducting a heating or cooling medium, with the grooves surrounding at least a half of the circumference of the pipe to securely hold the pipe in place on the plate, so that the heating or cooling medium conducted through the pipe can come into heat exchange relationship not only with an upper floor laid on top of the spacer plate but also with air conducted through space existing between the spacer plate and the underfloor.

Abstract: The invention relates to a flattened tubular film (1) made of thermoplastic material, in which the inner faces are not welded or glued, and are in mutual contact only over a part of their surface, thus forming a plurality of cells (3) of determined shape, essentially hermetic, containing a gas. The invention also relates to a process for manufacturing such a film, by extruding a preform, introducing a gas into the preform and flattening using at least one cylinder (2) whose surface has a relief such that, during the flattening, the two inner faces of the film come into mutual contact only over a part of their surface, thus forming a plurality of cells of determined shape, substantially hermetic, in which the said gas is imprisoned.

Abstract: Non-flat surfaces, such as domes with complex curves, are coated with particle specks of genuine gold deposited onto a film substrate layer. The particles are made from vapor deposited or sputter deposited genuine gold upon film laminates, which are preferably segmented and cut to form the genuine gold particle specks. These genuine gold particle specks are mixed in a resin binder and sprayed upon the non-flat surfaces, forming a visually seamless cover upon the non-flat surface.

Abstract: A single-electron transistor includes a projecting feature, such as a pyramid, that projects from a face of a substrate. A first electrode is provided on the substrate face that extends onto the projecting feature. A second electrode is provided on the substrate face that extends onto the projecting feature and that is spaced apart from the first electrode. At least one nanoparticle is provided on the projecting feature between the first and second electrodes. Accordingly, the geometric configuration of the projecting feature can define the spacing between the first and second electrodes.

Abstract: A rocket motor assembly is insulated or thermally protected with a rocket motor ablative material formed from a prepreg. The prepreg contains at least an impregnating resin matrix and, as a precursor prior to carbonization, either carded and yarn-spun solvent-spun staple cellulosic fibers, solvent-spun cellulosic filaments, or a combination thereof. When patterned and carbonized, the rocket motor ablative material can be lined or otherwise placed into a rocket motor assembly, such as between the solid propellant and case, in the bulk area of the exit nozzle liner, or at susceptible portions of a re-entry vehicle, such as the nose cone.

Abstract: A process for manufacturing a part includes the steps of molding a thermoplastic material into a generally planar sheet form having a textured surface on at least one side. The textured surface is defined by a plurality of protuberances with at least one side wall extending outwardly from the sheet. The thermoplastic material is molded with a predetermined pressure between a die and within a perforated insert. The molded thermoplastic material sheet and perforated insert are removed from the die after molding. The molded thermoplastic material sheet is sintered at a predetermined temperature for a predetermined period of time. The molded, sintered, thermoplastic material sheet is stripped from the perforated insert. The sheet can be masked for etching if desired. The sheet can be inserted into a molding die, where a dissimilar material is introduced into the die under pressure.

Abstract: Three-dimensional flexible adhesive film structures are described which exhibit tack on demand characteristics. The film is capable of showing minimal or no tack under normal handling conditions, but when pressed against a target surface, exhibits the desired adhesion.

Abstract: A lightweight composite article is described. The lightweight composite article comprises: (a) two substantially opposed plates, at least one of the plates is a metal plate; and (b) a support structure of thermoplastic material interposed between the plates, the support structure defining a plurality of hollow spaces. Each of the plates (a) is fixedly attached to the support structure (b) by means of a plurality of anchors, which are distributed substantially uniformly over the surface of each of the plates. The support structure may be in the form of a ribbed support structure and/or an egg-box shaped support structure. Also described are articles of manufacture which comprise the lightweight composite article of the present invention, e.g., automotive components.

Abstract: An article is disclosed that has a patterned surface containing alternating hydrophobic and hydrophilic surface regions. The hydrophobic regions may be sufficiently narrow such that under dew conditions moisture accumulated on the hydrophobic region migrates to the hydrophilic region, thus preventing the accumulation of water droplets. In frost conditions, the hydrophobic region remains relatively frost-free, thus maintaining at least partial transparency of the surface. Inorganic oxide particles on the surfaces of the hydrophobic regions may provide abrasion resistance. A method for making the patterned surfaces is disclosed in which a treatment removes organic binder to expose inorganic oxide particles at the surface of the hydrophilic regions.

Abstract: A multi-purpose reduced motion and anti-slip pad which is particularly suitable for substantially immobilizing a workstock as a tool is applied to the workstock. In a preferred embodiment the pad is constructed of vinyl plastisol and is characterized by a flexible, durable sheet having multiple, resilient, spaced-apart nodules of selected size and cross-sectional configuration extending from the sheet typically in multiple parallel, diagonal rows. Each of the nodules typically has a flat top surface, and multiple nodules contact and substantially immobilize the workstock as the workstock rests on the pad. In one embodiment, the parallel diagonal rows of the nodules are arranged in columns, with adjacent, parallel columns of nodules separated by a clear lane characterized by an absence of nodules on the sheet and on which a cylindrical workstock can be placed and immobilized. In another embodiment, the diagonal rows of nodules define a continuous field of the nodules on the sheet.

Abstract: A shock absorbing material for automobiles, having extremely good shock absorbing properties, capable of absorbing shocks applied to a passenger in a car at the time of a crash, or the like, and reducing the head injury criteria, comprising a rigid polyurethane foam having a compression stress of 3 kg/cm2 or more, with concavities arranged on at least one planar surface. In order to mount the head protecting material to a ceiling material, a trim, a car body, or the like, easily and securely, the head protecting material is mounted to the ceiling material, or the like, with an adhesive sheet comprising a base material made of a foam material with an adhesive layer formed thereon.

Abstract: A cargo liner and cargo holder system includes a mat having a plurality of protrusions extending from a base. Locking members include a plurality of engagement members extending from a body and are adapted to engage with the protrusions of the mat. The mat includes a plurality of geometrically-shaped protrusions which can be octagonally shaped or cylindrically shaped. The locking members can be secured to boxes or other objects for securement to the mat. Engagement members engaged to the mat are able to move to a limited extent; this motion allows each engagement member to be captured by mat protrusions with the same degree of capture force. The mat also includes a lip extending around the perimeter of the mat for containment of any liquids therein. The mat also includes two layers, a polyethylene first layer and an olefin-friendly rubber layer. The locking members can be modified and secured to a bag-hanging device.

Abstract: A cushion having an underlying polyurethane foam or flexible layer which includes a non-plane surface, and an overlying visco-elastic foam layer positioned adjacent to the non-plane surface of the underlying layer, the cushion being adapted for suitably supporting a load, such as a human body, positioned thereon.

Abstract: A floor covering (1) made of an elastically moldable material, in particular from a synthetic rubber, which is provided with a regular arrangement consisting of first projections (3) on the upper side (1a) and with a regular arrangement of second projections (5) on the underside (1b), the projections of the first projections and of the second projections not exhibiting any overlapping area on the plane of the covering and that, on the underside within the projections of the first projections, third projections (7) are provided in each case which have a smaller height vis-à-vis the second projections such that the floor covering only touches a floor with the second projections when it is in an unloaded state, however, when a preset load is exceeded locally, the third projections come in contact with the floor.

Abstract: Disclosed is an anisotropic conductive adhesive having an adhesive layer and conductive particles individually adhered to the adhesive layer, the conductive particles being arranged in an ordered array. The size of the conductive particles is at least somewhat smaller than the thickness of the adhesive layer. Also disclosed is an anisotropic conductive adhesive having an adhesive layer, conductive particles individually adhered to the adhesive layer, and a release liner having an ordered array of dimples. The conductive particles reside in a single layer in the dimples. The anisotropic conductive adhesive is made by placing the conductive particles in an ordered array of dimples on a low adhesion surface. An adhesive layer is then laminated on top such that the conductive particles individually adhere to the adhesive layer. The anisotropic conductive adhesive may be used to electrically connect fine pitch electrodes on opposing circuit layers.

Abstract: A sound-absorbing cellular component is produced in multiple-chamber array, using a grid of spaced elongate rods, and by engaging to the rods of said grid a foil of deformable sheet material which is then drawn by deformation through spaces between rods, to thereby define adjacent partition walls of adjacent chambers. Various embodiments are described, involving retention and/or removal of the rods, and/or involving application of one or more insulating or finishing materials continuously over outwardly facing bottoms of the chambers of the array.

Abstract: According to one aspect of the invention, a multi-layer automotive interior trim panel (10) comprises a decorative covering layer (12) and a supportive substrate layer (16). The substrate layer (16) is comprised of a rigid material formed into a predetermined shape for supporting the covering layer. The trim panel also includes an intermediate layer (18) disposed between the covering layer and the supportive substrate layer comprised of cushioning material. The intermediate layer includes a mat (20) of polymeric fibers, with the mat having a plurality of indentations (24) to provide a cushioning effect. A corresponding method for producing the interior trim panel having the three layers includes several steps. The first step is heating the cushion layer (18) to a predetermined temperature. The second step is melting a portion of the polymeric fibers in the cushion layer. The third step is stamping the cushion layer to form the plurality of indentations (24).

Abstract: A cargo liner and cargo holder system includes a mat having a plurality of protrusions extending from a base. Locking members include a plurality of engagement members extending from a body and are adapted to engage with the protrusions of the mat. The mat includes a plurality of geometrically-shaped protrusions which can be octagonally shaped or cylindrically shaped. The locking members can be secured to boxes or other objects for securement to the mat. The mat also includes a lip extending around the perimeter of the mat for containment of any liquids therein. The mat also includes two layers, a polyethylene first layer and an olefin-friendly rubber layer. The locking members can be modified and secured to a bag-hanging device. Movable side members can be secured to the locking members for securement of boxes to the mat. Also disclosed is a method for making the mat.

Abstract: A large-sized and heavy part (1) of plastic material is injection molded. Localized zones are created in which the thermal conductance of the part (1) is higher in the surface impressions (10) at the mold ejectors for the removal of the part after it has been molded. In a preferred embodiment, the outer surface of the part (1) has, at the surface impressions (10), clusters of closed-bottom pits (13) formed by grids of mini-ribs (11) and (12) arranged perpendicularly with respect to each other. The thickness of the part varies from a maximum value (S1) at the periphery of the cavity to a minimum value (S2) at the bottom of a substantial number of the pits (13).

Abstract: The cellular core structure building element is a three dimensional arrangement of pyramidal elements in a continuous rectangular pattern interconnected at their bases by a base plane panel. The pyramid elements are normally void internally to form a structurally strong, lightweight panel. The common pyramid structure is modified by truncating the top of the pyramid to form a top face and by flattening the side face edges to form edge faces thereby creating a pyramid with a top face, four side faces and four edge faces. For best strength as a construction or building material, two cellular core structure sheets are superimposed one on the other by inverting and offsetting one relative to the other such that when mated the pyramid elements of one sheet fit between the pyramid elements of the other such that mating faces may be attached. Continuous faces sheets may be added to the external faces of the structure.

Abstract: A substance delivery system has a three dimensional structure with outermost surface features and spaces for containing a substance. The substance has a level below the outermost surface features such that the substance is protected from inadvertent contact with external surfaces. The substance remains protected until the three dimensional structure is sufficiently deformed into a substantially two dimensional structure and the substance is thereby exposed to contact an external surface without compliance of the external surface being necessary. Deforming is preferably achieved by a compression force, wherein the outermost surface features of the three dimensional structure deform in a direction of the compression force.

Abstract: A reinforced composite matting is disclosed, to provide a foundation for the development of vegetation to stabilize the channel surface, as a cost effective and environmentally friendly alternative to rip rap or concrete channel lining. The reinforced composite matting is formed of a bottom netting, a cuspated netting having ridges and troughs extending across the width of the cuspated netting, with the troughs substantially adacent to the bottom netting, and a top netting substantially adacent to the ridges of the cuspated netting. A fiber matrix, preferably of strands of coconut fibers is disbursed between the bottom netting and the cuspated netting, and the bottom netting, fiber matrix, cuspated netting and top netting are secured together, preferably with thread, to form the reinforced composite matting of this invention.

Abstract: Described is an exhaust gas cleaning metallic substrate of the structure that three metallic honeycomb bodies are successively arranged within a metallic casing. Among the three metallic honeycomb bodies, (i) the metallic honeycomb bodies at front and rear positions have each been constructed by fixing a planar and corrugated bands as constituent members of said metallic honeycomb body at at least some of points of contact therebetween and also an outer peripheral wall of the metallic honeycomb body and an inner peripheral wall of the metallic casing at at least some of points of contact therebetween, and (ii) the metallic honeycomb body at a middle position has been constructed without fixing a planar and corrugated bands as constituent members of said metallic honeycomb body at points of contact therebetween and also an outer peripheral wall of the metallic honeycomb body and an inner peripheral wall of the metallic casing at points of contact therebetween.

Abstract: An arrangement in a protective membrane (1; 101; 201), particularly for floors (11; 111; 211), comprising a substantially plane membrane of a preferably rigid material, e.g.

Abstract: A method for stabilizing soil and reinforcing vegetation includes placing a single-layered, three-dimensional, high-profile woven geotextile fabric into the soil. The single-layered, homogeneous fabric is woven from monofilament yarns having different heat shrinkage characteristics such that, when heated, the fabric forms a thick three-dimensional, cuspated profile. The monofilament yarns have a relatively high tensile strength and a relatively high modulus at 10 percent elongation so as to provide a fabric which is greater in strength and more dimensionally stable than other geotextile structures. Thus, the geotextile fabric is suitable for use on slopes, ditches and other embankments and surfaces where erosion control, soil stabilization and/or vegetative reinforcement may be necessary. The homogeneous, single-component nature of the fabric promotes easier handling and minimizes failure points, while offering a thick, strong and dimensionally stable product upon installation.

Abstract: A hygienic sanitary towel of a rectangular planar shape formed of a first outer sheet, a second outer sheet, and a third inner sheet sandwiched between the outer sheets in a stacked registered press-fit relation and with each sheet formed of an absorbent pressed fiber material.

Abstract: A cushioning structure for dampening shocks useful as a packing material to protect shipments of goods and as a protective shield or garment to prevent injury from falls or increase comfort such as in shoes, furniture, carpet, automobile components etc. including one or more planar sheets of pliable material bonded to a matrix of polygon shape cells containing a fluid such as air or other gas. In one aspect the cells are in fluid communication with each other to provide a valved fluid transfer from one cell to the next. In another aspect, the material is a resilient material formed as a grid like matrix of shaped indentures.

Abstract: A roof construction has vibration dampening ability and includes a body member in contact with a waffle-like surface of a moulded porous compressed fibrous web which is designed to have a self-supporting stability. The waffle-like surface exhibits an anisotropic air resistant structure.

Abstract: A lift bag includes a plurality of independently inflatable chambers for controlling lifting of objects. Each chamber is defined by an upper surface sheet and a lower surface sheet, the upper surface sheet of one chamber positioned below an adjacent chamber being securely attached to the lower surface sheet of an adjacent chamber. The lift bag can be operated at pressures of about 15 psig at specified heights which allows greater flexibility compared to conventional, single-chambered lift bag which operate at pressures of about 7 psig. Preferably, all seams, reinforcements, and fittings are vulcanized in place using uncured rubber coated fabric. Grommets or other securing means may provide further stability to the lift bag.

Abstract: A building component in the form of a board-like distance plate having a lattice of horizontal and vertical ribs. Frusto-pyramid projections (3) extend from the intersections of the ribs on one side of the board and domes (4) extend from the other side of the board between the ribs and cover a larger surface area than the projections (3). The domes form cavities which are interconnected by virtue of the projections spacing the plate from a wall or other surface.

Abstract: The pad, of round or polygonal shape, has two compressed outer surfaces, and an entirely or nearly uncompressed body. The more highly compressed the surfaces, the less permeable the pad becomes to liquids and substances having the consistency of a salve. The pads are suitable for applying and/or absorbing liquid or semi-liquid materials in cosmetics, medicine end numerous fields of technology.

Abstract: A floor mat is provided with a generally flat upper wall with a multitude of y-shaped ribs extending vertically downward from the upper wall to a floor surface, supporting the mat. Each of the y-shaped ribs has a solid central core with three legs which extend horizontally radially outward from the core. The distal end of each of the legs is bulbously enlarged. The ribs are spaced apart in a symmetrical pattern so that two sides of three adjacent ribs cooperatively define a generally cylindrical pocket. The pocket, while forming an enclosure, nevertheless had lateral openings at three equally spaced locations formed by the ends of each of two adjacent ribs being spaced slightly apart allowing for ingress and egress of air from the pocket. Located above the center of each pocket is a hollow dome formed in the upper wall.

Abstract: The present invention is directed to a resealable bond between two or more overlapping multi-layer film surfaces comprising a plurality of closely spaced, interconnecting indentations. More specifically, the releasable seal of the present invention is directed to the simultaneous embossing of precisely configured indentations, involving multilayer films which can heat seal together during the embossing operation; the resulting seal layer is designed and configured to delaminate and tear when the package is initially opened, while the indentations are designed and configured to re-engage and partially re-seal when the package is later closed.

Abstract: A heavy duty rubber composite having a reinforcement structure is described, wherein the reinforcement structure is composed of a network material made from a three-dimensionally shaped textile material forming an open-mesh three-dimensional network which penetrates the rubber material three-dimensionally in a skeleton-like manner.

Abstract: A twin sheet plastic panel structure, a twin sheet plastic pallet utilizing the panel structure, and a methodology for forming the panel structure and pallet. The panel structure is formed by thermoforming an upper plastic sheet to include rows of hollow bosses extending downwardly from the main body of the sheet; thermoforming a lower plastic sheet to include rows of hollow bosses extending upwardly from the main body portion of the sheet; and bringing the sheets together while still in a heated flowable state to position the bosses of the upper sheet in intermeshing relation to the bosses of the lower sheet so that the annular side wall portions of the upper and lower bosses fuse together, the bottom walls of the upper sheet bosses are fused to the upper surface of the main body portion of the lower sheet, and the upper walls of the lower sheet bosses are fused to the lower surface of the main body portion of the upper sheet to form a series of parallel rigid column structures between the sheets.

Abstract: A twin sheet plastic panel structure, a twin sheet plastic pallet utilizing the panel structure, and a methodology for forming the panel structure and pallet. The panel structure is formed by thermoforming an upper plastic sheet to include rows of hollow bosses extending downwardly from the main body of the sheet; thermoforming a lower plastic sheet to include rows of hollow bosses extending upwardly from the main body portion of the sheet; and bringing the sheets together while still in a heated flowable state to position the bosses of the upper sheet in intermeshing relation to the bosses of the lower sheet so that the annular side wall portions of the upper and lower bosses fuse together, the bottom walls of the upper sheet bosses are fused to the upper surface of the main body portion of the lower sheet, and the upper walls of the lower sheet bosses are fused to the lower surface of the main body portion of the upper sheet to form a series of parallel rigid column structures between the sheets.