Thermoformed platform

An article made in accordance with the procedure comprising:

• (a) extruding a continuous web of thermoplastic having a top surface and a bottom surface;
• (b) conveying the continuous web of thermoplastic through a scuffing work station where after the top surface is characterized having increased surface area relative the bottom surface;
• (c) shearing the continuous web of thermoplastic providing a plurality of sheets having scuffed top surfaces;
• (d) heating a first sheet;
• (e) forming the first sheet with a first mold;
• (f) heating a second sheet;
• (g) forming the second sheet with a second mold;
• (h) aligning the first mold with the second mold so a scuffed top surface of the first sheet faces a bottom surface of the second sheet:
• (i) moving the first mold toward the second mold;
• (j) joining together sections of the scuffed top surface of the first sheet with sections of the bottom surface of the second sheet to form a twin sheet subassembly;
• (k) heating a third sheet;
• (l) forming the third sheet with a third mold;
• (m) aligning the third mold with the twin sheet subassembly;
• (n) moving the twin sheet subassembly toward the third mold;
• and,
• (o) joining together sections of a scuffed top surface of the twin sheet subassembly with sections of the bottom surface of the third sheet to form a triple sheet article.

A pallet made in accordance with the method comprising:

• (a) extruding a continuous web of thermoplastic having a top surface and a bottom surface;
• (b) conveying the continuous web of thermoplastic through a scuffing work station where after the top surface is characterized having increased surface area relative the bottom surface;
• (c) shearing the continuous web of thermoplastic providing a plurality of sheets having scuffed top surfaces;
• (d) heating a first sheet;
• (e) forming the first sheet with a first mold;
• (f) heating a second sheet;
• (g) forming the second sheet with a second mold;
• (h) aligning the first mold with the second mold so a scuffed top surface of the first sheet faces a bottom surface of the second sheet:
• (i) moving the first mold toward the second mold;
• (j) joining together sections of the scuffed top surface of the first sheet with sections of the bottom surface of the second sheet to form a twin sheet subassembly;
• (k) heating a third sheet;
• (l) forming the third sheet with a third mold;
• (m) aligning the third mold with the twin sheet subassembly;
• (n) moving the twin sheet subassembly toward the third mold;
• and,
• (o) joining together sections of a scuffed top surface of the twin sheet subassembly with sections of the bottom surface of the third sheet to form a triple sheet pallet.

An article resistant to fire and the heat of fire, the article comprising:

• a first sheet of thermoformable plastic, comprising a surface layer of an intumescent polyolefin composition resistant to fire and an interior substrate layer of a polyolefin resin, provided in a co-extrusion construction molded over a first mold to provide a first surface;
• a second sheet as in the first sheet molded over a second mold to provide a second surface;
• a third sheet of thermoformable plastic composed of at least one layer of polyolefin resin molded over a third mold to provide a rigid member comprising an array of upward extending ribs, an array of downward extending channels and between the ribs and channels hollow areas containing dead air space;
• the third sheet being compressed between the first and second sheets upon a machine frame to provide a rigid unitary structure wherein upper surfaces of the ribs bond to the interior substrate layer of the first sheet and lower surfaces of the channels bond to the interior substrate layer of the second sheet;
• the surface layers of the intumescent polyolefin compositions of the first and second sheets being exteriorly visible preventing the interior substrate layers of the first and second sheets from supporting a flame upon exposure to fire;
• and
• the surface layers of the intumescent polyolefin compositions of the first and second sheets and the dead air space insulating the third sheet, the third sheet resisting the heat of the fire to remain rigid.