Importance

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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. The heated thermoplastic sheet has a temperature that is sufficient to melt-bond the thermoplastic layer defining the second surface of the first plastic sheet and the first surface of the heated thermoplastic sheet together, thereby resulting in the continuous formation of a heated multilayered thermoplastic sheet (292) having a thermoformable temperature. The second surface (298) of the heated thermoformable multilayered thermoplastic sheet is brought into contour matching contact with the interior surface (14) of a first mold portion (11), and cooled thereby resulting in formation of the shaped multilayered article. A sheet molding apparatus (1), a sheet guide apparatus (456, 603), and fluid management structures (700) (e.g., storm/waste water management chambers) prepared thereby, are also provided with regard to the present invention.

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First Claim