Dale E Polk

US Patent:

20030232176, Dec 18, 2003

Filed:

Nov 13, 2002

Appl. No.:

10/293005

Inventors:

Dale Polk - Titusville FL, US

International Classification:

B32B003/28
B29C043/34

US Classification:

428/167000, 264/271100, 264/325000, 264/040100, 425/166000, 425/209000, 425/406000, 425/145000, 425/113000

Abstract:

A system and method for forming an article from thermoplastic material and fiber. The method includes heating thermoplastic material to form a molten thermoplastic material for blending with the fiber. The molten thermoplastic material is blended with the fibers to form a molten composite material having a concentration of fiber by weight. The molten composite material may then be extruded through dynamic dies to deliver discrete controlled material that is gravitated onto a lower portion of a mold. The lower portion of the mold may be moved in space and time while receiving the flow of composite material to deposit a predetermined quantity of molten composite material thereon conforming to mold cavities of the lower and an upper portion of the mold. The upper portion of the mold may be pressed against the predetermined quantity of molten composite material and closing on the lower portion of the mold to form the article.

US Patent:

20040241386, Dec 2, 2004

Filed:

Jul 6, 2004

Appl. No.:

10/885329

Inventors:

Dale Polk - Titusville FL, US

International Classification:

B29C043/02

US Classification:

428/113000, 264/319000, 264/040700, 425/145000, 425/576000, 264/328100

Abstract:

A system and method for forming an article from thermoplastic material and fiber. The method includes heating thermoplastic material to form a molten thermoplastic material for blending with the fiber. The molten thermoplastic material is blended with the fibers to form a molten composite material having a concentration of fiber by weight. The molten composite material may then be extruded through dynamic dies to deliver discrete controlled material that is gravitated onto a lower portion of a mold. The lower portion of the mold may be moved in space and time while receiving the flow of composite material to deposit a predetermined quantity of molten composite material thereon conforming to mold cavities of the lower and an upper portion of the mold. The upper portion of the mold may be pressed against the predetermined quantity of molten composite material and closing on the lower portion of the mold to form the article.

US Patent:

20040253429, Dec 16, 2004

Filed:

Mar 31, 2004

Appl. No.:

10/815310

Inventors:

Dale Polk - Titusville FL, US

International Classification:

B32B003/00

US Classification:

428/292100

Abstract:

A system and method for forming an article from thermoplastic material and fiber. The method includes heating thermoplastic material to form a molten thermoplastic material for blending with the fiber. The molten thermoplastic material is blended with the fibers to form a molten composite material having a concentration of fiber by weight. The molten composite material may then be extruded through dynamic dies to deliver discrete controlled material that is gravitated onto a lower portion of a mold. The lower portion of the mold may be moved in space and time while receiving the flow of composite material to deposit a predetermined quantity of molten composite material thereon conforming to mold cavities of the lower and an upper portion of the mold. The upper portion of the mold may be pressed against the predetermined quantity of molten composite material and closing on the lower portion of the mold to form the article.

US Patent:

20040253430, Dec 16, 2004

Filed:

Jul 6, 2004

Appl. No.:

10/885218

Inventors:

Dale Polk - Titusville FL, US

International Classification:

B32B003/00

US Classification:

428/292100

Abstract:

A system and method for forming an article from thermoplastic material and fiber. The method includes heating thermoplastic material to form a molten thermoplastic material for blending with the fiber. The molten thermoplastic material is blended with the fibers to form a molten composite material having a concentration of fiber by weight. The molten composite material may then be extruded through dynamic dies to deliver discrete controlled material that is gravitated onto a lower portion of a mold. The lower portion of the mold may be moved in space and time while receiving the flow of composite material to deposit a predetermined quantity of molten composite material thereon conforming to mold cavities of the lower and an upper portion of the mold. The upper portion of the mold may be pressed against the predetermined quantity of molten composite material and closing on the lower portion of the mold to form the article.

US Patent:

20060008967, Jan 12, 2006

Filed:

May 31, 2005

Appl. No.:

11/140727

Inventors:

Dale Polk - Titusville FL, US

International Classification:

H01L 21/8238

US Classification:

438202000

Abstract:

A system and method for forming an article from thermoplastic material and fiber. The method includes heating thermoplastic material to form a molten thermoplastic material for blending with the fiber. The molten thermoplastic material is blended with the fibers to form a molten composite material having a concentration of fiber by weight. The molten composite material may then be extruded through dynamic dies to deliver discrete controlled material that is gravitated onto a lower portion of a mold. The lower portion of the mold may be moved in space and time while receiving the flow of composite material to deposit a predetermined quantity of molten composite material thereon conforming to mold cavities of the lower and an upper portion of the mold. The upper portion of the mold may be pressed against the predetermined quantity of molten composite material and closing on the lower portion of the mold to form the article.

US Patent:

20070164481, Jul 19, 2007

Filed:

Nov 21, 2006

Appl. No.:

11/602780

Inventors:

Dale E. Polk - Titusville FL, US

International Classification:

B29C 43/02
B29C 59/02
B29C 51/08

US Classification:

264320, 264322

Abstract:

A molded panel is provided, which includes a body and a plurality of supporting members. The body includes a generally planar top surface and a bottom surface. The supporting members extend from the bottom surface of the body to define a support structure. The support structure includes a top surface adjacent to the bottom surface of the body, a generally planar bottom surface and at least one edge extending therebetween. The support structure also includes at least one channel extending along a central x-axis of the support structure, and at least one additional channel intersecting the at least one central channel and extending along a y-axis of the support. The y-axis is generally perpendicular to the x-axis. A connection system for the molded panel, systems including the molded panel, and methods related to the molded panel are also described.

US Patent:

20080057285, Mar 6, 2008

Filed:

Aug 30, 2006

Appl. No.:

11/512504

Inventors:

Dale E. Polk - Titusville FL, US

International Classification:

B29C 45/16
B32B 27/04

US Classification:

4282991, 264255

Abstract:

In accordance with the present invention, there is provided a method of forming a molded plastic article () having a second surface () with molded extensions (), e.g., structural supports, such as ribs, extending therefrom, and a first surface () that is substantially free of sink mark defects. The method involves forming, from a first plastic material, a first molded section () having at least one molded extension () extending from the second surface () thereof. The molded extension () is formed in a mold recess () having a reversibly positionable slide () therein. After formation of the first molded section (), the slide () is retracted to a second slide position (B) thus forming within the molded extension a retainer cavity () that is in fluid communication with an aperture () in the first surface () of the first molded section (). A second plastic material is introduced into the mold () over the first molded section (), and a portion thereof passes through the aperture () and into the retainer cavity (), thereby forming a second molded section () that is continuous with each retainer (). The first and second molded sections, which together form the molded article (), are fixedly attached to each other by at least one molded retainer (), and the first surface () of the second molded section, which defines the first surface () of the molded article (), is substantially free of sink mark defects. The present invention also relates to a molded article.

US Patent:

20080057286, Mar 6, 2008

Filed:

Aug 30, 2006

Appl. No.:

11/512792

Inventors:

Dale E. Polk - Titusville FL, US
Albert H. Berghuis - Titusville FL, US

International Classification:

B29C 45/16
B32B 27/04

US Classification:

4282991, 264255

Abstract:

In accordance with the present invention, there is provided a method of forming a molded plastic article having at least one molded extension extending from a second surface thereof, and a first surface that is substantially free of sink mark defects. The method involves providing a mold () that includes a first mold portion () having a recess () therein. At least a portion of the base () of the recess () is defined by the upper surface () of a part ejector (). A first plastic material is introduced into the recess () so as to form a molded extension (). After at least partial solidification of the molded extension (), the part ejector () is positioned so as to push the upper surface () and upper portion () of the molded extension out of the recess (), while a lower portion () of the molded extension remains within the recess. A second plastic material is introduced into the mold so as to form a molded body () in which the upper surface () and upper portion () of the molded extension () are immersed and embedded. The lower portion () of the molded extension extends from the second surface () of the molded body (), and the first surface () of the molded body is substantially free of sink mark defects opposite the molded extension. The molded plastic article includes both the molded body () and molded extension (). The present invention also relates to a molded plastic article.