A hydro-formed film includes a polymeric web having a first substantially planar surface and a second substantially planar surface opposite the first substantially planar surface, and a plurality of three-dimensional micro-apertures extending from the first substantially planar surface. The plurality of three-dimensional micro-apertures have a mesh count in a range of about 40 to about 75 apertures per linear inch. The hydro-formed film has a Compression Sensor Point (CSP) count of at least about 80.

A thermoforming system for forming a cushioning pod structure that includes a first and a second thermoforming station with each comprised of a film holder and a thermoforming mold holder. The system implements a thermal source that is moveable between the first thermoforming station and the second thermoforming station such that the film holders are between the thermal source and the respective thermoforming mold holder. The system also relies on intentional application of a vacuum source fluidly coupled to thermoforming stations and a movement mechanism configured to move the thermal source between the first thermoforming station and the second thermoforming station. Additional aspects contemplate the implementation of a positive pressure source to aid in the dislodgment of the formed portion, a cooling system to adjust mold temperatures, and/or a fan to efficiently thermoform the component.

A thermoforming system for forming a cushioning pod structure that includes a first and a second thermoforming station with each comprised of a film holder and a thermoforming mold holder. The system implements a thermal source that is moveable between the first thermoforming station and the second thermoforming station such that the film holders are between the thermal source and the respective thermoforming mold holder. The system also relies on intentional application of a vacuum source fluidly coupled to thermoforming stations and a movement mechanism configured to move the thermal source between the first thermoforming station and the second thermoforming station. Additional aspects contemplate the implementation of a positive pressure source to aid in the dislodgment of the formed portion, a cooling system to adjust mold temperatures, and/or a fan to efficiently thermoform the component.

Provided is a resin panel without warpage, in which weight reduction and high rigidity of the resin panel have been promoted. The resin panel according to an aspect of the present invention is a resin panel having a back wall, a front wall facing the back wall with a gap therebetween, and ribs formed by having portions of the back wall depressed toward the front wall and welded to the inner surface of the front wall, characterized in that the back wall, the front wall and the ribs are configured by mold-clamping, in a split mold, a first molten resin in a molten state and incorporating a plate-shaped filler, which constitutes the back wall, and a second molten resin in a molten state and incorporating a plate-shaped filler, which constitutes the front wall, the first molten resin and the second molten resin having been extruded and flowed out from an extrusion apparatus, and the longitudinal direction of the ribs is non-parallel to the direction of flow of the first molten resin and the second molten resin.

Provided is a resin panel without warpage, in which weight reduction and high rigidity of the resin panel have been promoted. The resin panel according to an aspect of the present invention is a resin panel having a back wall, a front wall facing the back wall with a gap therebetween, and ribs formed by having portions of the back wall depressed toward the front wall and welded to the inner surface of the front wall, characterized in that the back wall, the front wall and the ribs are configured by mold-clamping, in a split mold, a first molten resin in a molten state and incorporating a plate-shaped filler, which constitutes the back wall, and a second molten resin in a molten state and incorporating a plate-shaped filler, which constitutes the front wall, the first molten resin and the second molten resin having been extruded and flowed out from an extrusion apparatus, and the longitudinal direction of the ribs is non-parallel to the direction of flow of the first molten resin and the second molten resin.

A highly flexible thermoformed stand-up dispensing package for a flowable material that is produced from one or more highly flexible heat-sealable polymeric sheets is formed with a trapezoidal front wall and opposing back wall and is dimensional and configured so that the corner of the package formed by the intersection of the top and the projecting side wall, or walls, that extend at an obtuse angle from the base is removable along a weakened tear line that is positioned upon removal to provide an integral pour spout for the controlled dispensing of the flowable material; and the container portion of the package is dimensioned to (1) maintain the center of gravity of the flowable material in the package over the base wall when the base wall of the filled package is in contact with a horizontal surface, and (2) to maintain the level of flowable material in the opened package is below the opened integral pour spout.

A thermoforming apparatus is described herein. The apparatus may include a pressure mechanism, a thermal device, a plurality of individually actuatable pins, and/or a pin actuation mechanism. The pressure mechanism may create a force against a die surface. The thermal device may change a thermal state of a material forced by the pressure mechanism against the die surface. The plurality of individually actuatable pins may form the die surface. The pin actuation mechanism may be connected to the plurality of actuatable pins and/or may actuate the pins. This apparatus improves on prior solutions in many ways. For example, embodiments of the thermoforming apparatus may require significantly less time between different molds than previous thermoforming machines and 3D printers.

A thermoforming apparatus is described herein. The apparatus may include a pressure mechanism, a thermal device, a plurality of individually actuatable pins, and/or a pin actuation mechanism. The pressure mechanism may create a force against a die surface. The thermal device may change a thermal state of a material forced by the pressure mechanism against the die surface. The plurality of individually actuatable pins may form the die surface. The pin actuation mechanism may be connected to the plurality of actuatable pins and/or may actuate the pins. This apparatus improves on prior solutions in many ways. For example, embodiments of the thermoforming apparatus may require significantly less time between different molds than previous thermoforming machines and 3D printers.

A method of manufacturing a cover for a spa includes the steps of vacuum molding a first shell member and a second shell member, bringing the first and second shell members into registration with one another to define a hollow cavity therebetween, and injecting a foam into the hollow cavity, wherein the foam is configured to bond with the shell members to create a unitary structural part that provides increased strength and rigidity.

A method of manufacturing a cover for a spa includes the steps of vacuum molding a first shell member and a second shell member, bringing the first and second shell members into registration with one another to define a hollow cavity therebetween, and injecting a foam into the hollow cavity, wherein the foam is configured to bond with the shell members to create a unitary structural part that provides increased strength and rigidity.