A molding die device is provided for bringing a resin sheet into close contact with a pair of dies by vacuum suction from a cavity surface to perform molding. An outer frame portion is formed integrally with an outer peripheral portion of the respective dies arranged to face each other. Moreover, one of the dies has a recessed portion formed at the position of the one of the dies facing the outer frame portion of the other die and configured so that the outer frame portion of the one of the dies can be housed in the recessed portion. The outer frame portion is formed to protrude most in each die. Upon molding, the dies are clamped together after vacuum suction has been performed with the resin sheet being arranged in contact with the outer frame portions.

A method for manufacturing a fuel tank is described herein. The method includes subsequent to molding of a housing of a fuel tank, positioning a strut inside the housing. The method additionally includes snap-fitting a flexible projection of the strut with a corresponding flange section in a first wall of the housing, the flange section surrounding an opening in the first wall of the housing and the flexible projection including a surface overlapping an interior surface of the flange section subsequent to the snap-fitting.

A fluid-filled chamber may include a pair of polymer layers that define a plurality of subchambers and a web area. The subchambers are protruding portions of the polymer layers that enclose a fluid, and the web area is portions of the polymer layers that are located between the subchambers and lay adjacent to each other. The subchambers may have greater thickness than the web area. A perimeter bond joining the polymer layers and extends around a periphery of the chamber. In addition, a plurality of interior bonds join the polymer layers and extend around the subchambers, which may seal the fluid within the subchambers.

A belly pan includes a first sheet having at least one energy management feature and a second sheet having a smooth aerodynamic surface. The first sheet is bonded to the second sheet. The belly pan is produced utilizing a twin sheet vacuum forming process.

A resin panel includes a first structure and a second structure stacked on each other. The structures includes reference surfaces that serve as the front surface and the back surface of the resin panel respectively. Each of the structures includes a plurality of protrusions protruding inwardly from the reference surface. The protrusions of the structure face the protrusions of the other structure each other. Jutting portions of linear shape are formed between adjacent protrusions of each of the structures. The structures are joined such that apical portions of the protrusions of each structure abut one another.

A method of forming a vacuum insulated refrigerator cabinet structure includes providing a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer structural layers. The barrier material and the first and second outer layers comprise thermoplastic polymers. The multi-layer sheet of material is thermoformed to form a non-planar first component having a central portion and four sidewalls extending transversely from the central portion. The method further includes securing a second component having a central portion and four sidewalls extending transversely from the central portion to the first component to form an interior space therebetween. Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space. The first and second components are sealed together to form a vacuum insulated refrigerator cabinet structure.

A method for producing a plastic container from a first plastic half-shell and a second plastic half-shell, with a first attachment permanently fastened to the first plastic half-shell.

The invention relates to a method for producing a container from thermoplastic material having a connection element (5) passing through the wall thereof. The method comprises making available at least one plate-shaped or shell-shaped or tube-shaped preform (3) made of plasticized thermoplastic material, introducing the preform (3) into a multipart molding tool (1) having cavities defining at least one molding recess, molding and final shaping of the preform (3) within the molding tool (1) using differential pressure, piercing of the still warm-plastic preform (3) from the tool side by means of a mandrel (9) in order to produce an opening (6) in the preform (3), insertion from the molding recess side of a connection element (5) into the opening (6) produced by the mandrel (9), and connection of the connection element (5) to the preform (3).

A core member for a sandwich panel and a method of forming the core member for the sandwich panel which are capable of attaining a desired profile, a desired pattern on their surfaces, and a desired inner structure in accordance with an application of the sandwich panel. There is provided a thermoplastic resin core member interposed between two resin skin sheets comprising a closed hollow portion located to be inside of a desired position in accordance with an application of the sandwiched panel, and it is formed by clamping parison of a molten thermoplastic resin positioned to be between two split molds so as to exhibit a desired profile and/or a surface shape, two surfaces against each of which the molten parison is pressed to form an adhesive surface on which the corresponding resin skin sheet is formed.

A multi-sheet component for a utility vehicle that includes at least one gap between at least two of the sheets, thereby providing a component that enhances worker safety by increasing component stiffness and reducing component thickness. The component is manufactured through multi-sheet thermoforming and uses a conical frustum corrugation to increase stiffness.