Patent Publication Number: US-2004046273-A1

Title: System and method for molding a basketball backboard

Description:
RELATED APPLICATION  
     [0001] This application is a continuation-in-part of application Ser. No. 08/220,906 filed Mar. 31, 1994. 
    
    
     
       BACKGROUND OF THE INVENTION  
       [0002] 1. Field of the Invention  
       [0003] This invention relates to a system and method for molding parts, and more particularly, a system and method for molding parts from contaminated molding materials using a single thermal heat rise.  
       [0004] 2. Description of Related Art  
       [0005] In the field of thermoplastic molding, it is common to mold parts using either an injection or compression molding process. Due to the size of the orifices used in the injection molding equipment, it is often difficult to injection mold with reinforcing fibers, such as glass fibers, having a length over one-eighth inch because such fibers are not easily injected into or conveyed through the injection mold equipment. In addition, it is difficult to use contaminated molding materials such as those collected in plastics recycling programs unless they have been substantially cleaned, processed and put into a usable form and size prior to being used in the injection molding equipment. Such cleaning and processing are expensive and can substantially increase the cost of using the contaminated materials, thereby making them economically impractical.  
       [0006] Another problem with the thermoplastic processes of the past is that the thermoplastics become degraded and lose, for example, their strength when exposed to multiple heat rises.  
       [0007] In general, there are two basic types of compression molding processes which may be used for molding thermoplastics. First, a sheet molding process involves placing a reinforcement, such as a glass mat, between sandwiching layers of a thermoplastic and heating the materials to produce a single sheet of material. The single sheet of material is then cut to the desired size and then reheated to molding temperature before being placed in a compression molding press. This process has the disadvantage of higher cost because of the apparatus required, the material handling costs incurred in making the sheet, handling and cutting the sheet, and the like. The material used to make the sheet is also subject to three thermodynamic cycles, a first cycle when the thermoplastic sheet is formed, a second cycle when the thermoplastic sheets and glass mat are molded together, and a third cycle when the resulting sheet is heated to molten temperature prior to molding the part.  
       [0008] The second form of thermoplastic compression is bulk molding compounds by producing a billet of molten material that is placed into a compression molding press which molds the molten material into a part. Effectively placing and distributing long reinforcing fibers in the billet has heretofore required complex machinery. For example, U.S. Pat. No. 5,165,941 issued to Ronald C. Hawley on Nov. 24, 1992, discloses an extruder apparatus and process for compounding thermoplastic resin and fibers. The Hawley extruder includes an apparatus for compounding thermoplastic resin and reinforcing fibers incorporating a resin extruder in which thermoplastic resin pellets are melted in a second, compounding, extruder in which the molten thermoplastic resin is mixed in intimate contact with long reinforcing fibers. The melted thermoplastic resin is not fed into the device with the fibers, but rather is introduced into the compounding extruder at a point downstream of the inlet point for reinforcing fibers, so that the fibers are mechanically worked and heated before coming into contact with heated, molten thermoplastic resins.  
       [0009] The Hawley device generally suffers from complexity that raises the investment and maintenance costs.  
       [0010] The compression molding of products using polymeric material and glass fibers has traditionally produced a material referred to as fiber glass reinforced plastic. This material exhibits characteristics better than the reinforced plastics, but does not exhibit strength, elasticity or impact resistance comparable to thermoplastic materials which are specifically designed to exhibit these characteristics. Most fiberglass reinforced plastic currently in the market is thermoset and is essentially a solidified mixture of fiber glass and plastic without benefit of chemical bonding or specific methods of enhancing polymer entrapment of the glass fibers because the glass fibers are merely immobilized in the resin in which it is embodied.  
       [0011] In addition, thermoset materials are generally not recyclable other than as filler materials, while thermoplastic materials can be remelted and remolded.  
       [0012] In the field of molded parts, many products are currently made from a variety of materials using moldable plastic. In the sporting goods field for example, example, bicycles, basketball backboards, toy vehicles and the like are commonly produced using multiple plastic materials. Compression molding has been a common method for producing basketball backboards and related parts of basketball goal assemblies, such as the support pull for the basketball backboard for many years. Heretofore, compression molding of basketball backboards and related parts has typically been limited to thermoset materials, which is characterized by placement of a cold charge in a compression mold. Thermoset process materials have certain drawbacks, including the fact that these material are generally not recyclable other than as filler materials. In general, there are two basic types of compression molding processes which may be used for molding thermoplastics. The following description of these two processes outline some of the difficulties that have prevented use of compression molding thermoplastics in the basketball goal assembly field.  
       [0013] The first type is a sheet molding process that involves a reinforcement, such as a glass mat, between sandwiching layers of a thermoplastic and heating the materials to produce a single sheet of material. The single sheet of material is then cut to the desired size and then reheated to molding temperature before being placed in a compression molding press. This process has the disadvantage of higher cost because of the apparatus required, the material handling cost incurred in making the sheet, handling and cutting the sheet, and the like. The material used to make the sheet is also subject to three thermodynamic cycles, a first cycle when the thermoplastic sheet is formed, a second cycle when the thermoplastic sheets and glass mat are molded together, and a third cycle when the resulting sheet is heated to molted temperature before molding the part.  
       [0014] A second form of thermoplastic compression is bulk molding compounds by producing a billet of molten material that is placed into a compression molding press which molds the molten material into a part. Effectively, placing and distributing long reinforcing fibers in the billet has heretofore required complex machinery as discussed in detail in parent application Ser. No. 08/220,906.  
       [0015] In addition, in recent years it has been increasingly common to provide graphics on the front face of molded parts, including the backboard, for a variety of reasons, such as aesthetic appeal to the consumer, product and source identification, and the like. However, the only commercially acceptable method of applying graphics have been silk-screened with inks or by applying decals.  
       [0016] Silk-screening is time consuming and tends to fade after prolonged exposure to sunlight and the elements. Decals are also expensive and can peel off after time.  
       [0017] An example of a prior art basketball backboard with silk-screen graphics is a backboard sold as “ShurShot”. The silk-screen ShurShot backboard is believed to be about 48 inches across and mates a structurally foam polystyrene molded in a multiple-port injection process. The backboard is molded in the natural color of polystyrene, which is milky white. The entire ShurShot backboard is subsequently spray painted both to seal the polystyrene and to protect the backboard from ultraviolet radiation. Finally, graphics are silk-screened on the front face of the backboard.  
       [0018] In some prior art applications, a graphics display was printed on a styrene sheet and laid by hand into a mold for forming the backboard. Alignment of the sheet was accomplished by aligning holes in the sheet on pins in the mold provided for producing the mounting holes in the backboard. Upon injecting styrene into the mold, the back portion of the graphics sheet melted to cause it to be joined to the face of the backboard. As styrene is relatively easy to print on, its use in this prior art process was conducive to the production of backboards provided with sheets having graphics printed thereon.  
       [0019] One of the problems encountered with printing on parts or backboards molded using the system of the parent application Ser. No. 08/220,906 was that printing on polyolefin materials was difficult because the polyolefin-based materials were relatively non-porous and, therefore, not receptive to printing inks.  
       [0020] What is needed, therefore, is an apparatus and method for molding thermoplastic parts which is simple and economical and which preserves the length of the reinforcing fibers, evenly distributes the reinforcing fibers or any other filler materials while maintaining flexibility of the material type in products fabricated, is capable of capitalizing on use of various contaminated thermoplastics to allow use of post consumer recycled material, and which provides a compounding and fabrication environment which promotes chemical bonding and molecular orientation to enhance the characteristics of the molded part.  
       [0021] The foregoing also demonstrates the need for a compression molding apparatus and method for making parts, such as sporting goods equipment including basketball backboards from recycled thermoplastic materials without requiring the extensive cleaning and processing that heretofore has made use of thermoplastics for these products in practical. There is also a need to improve the in-mold graphics process to permit the basketball backboard and other plastic molded parts of basketball goal assemblies to be compression molded with thermoplastic resin materials having improved in-molded graphics.  
       SUMMARY OF THE INVENTION  
       [0022] It is therefore a primary object of this invention to provide a method and apparatus which facilitates overcoming one or more of the aforementioned problems.  
       [0023] In one aspect of the invention, this invention comprises a plasticator for creating a billet of moldable material including a feeder for receiving a plurality of molding materials comprising a predetermined amount of a polyester, other carbocyclic and reinforcing fibers and a suspender coupled to said feeder for receiving the molding materials, for creating a molten suspension of the molding materials without damaging a substantial number of the reinforcing fibers, and also for creating the billet.  
       [0024] In one aspect of the invention, this invention comprises a plasticator for creating a billet of moldable material including a feeder for receiving a plurality of molding materials comprising a predetermined amount of a polyester, other carbocylics and reinforcing fibers, and a suspender coupled to the feeder for receiving the molding materials, for creating a molten suspension of the molding materials without damaging a substantial number of the reinforcing fibers, and also for creating the billet.  
       [0025] In another aspect of the invention, this invention comprises a method for creating a billet for molding a part comprising the steps of (a) loading a plasticator with molding materials, the molding materials comprising a polyester, other carbocylics and reinforcing fibers, (b) heating the molding materials to a predetermined temperature, (c) blending the molding materials in order to create a molten suspension wherein a majority of the reinforcing fibers remain generally undamaged, and (d) extruding the molten suspension in order to form a billet having preselected billet characteristics.  
       [0026] In yet another aspect, this invention comprises a plasticator for creating a billet from a plurality of molding materials, the plasticator comprising plasticating means for receiving the molding materials and for creating a molten suspension of the molding materials, and control means associated with the plasticating means for controlling the suspension characteristics applied to the molding materials in order to plasticity the plurality of molding materials into a billet having predetermined billet characteristics.  
       [0027] In still another aspect, this invention comprises a system for molding a part comprising a plasticator for creating a billet from a plurality of molding materials, the plasticator comprising plasticating means for receiving the molding materials and for creating a molten suspension of the molding materials, control means associated with the plasticating means for controlling the suspension characteristics applied to the molding materials in order to plasticity the plurality of molding materials into a billet having predetermined billet characteristics, and a press having a mold for receiving the billet and for molding the billet into the part.  
       [0028] In yet another aspect, this invention comprises a plasticating process comprising the steps of loading a plasticator with a plurality of molding materials, creating a mixture with the plurality of molding materials in the plasticator, and plasticating the mixture of the plurality of molding materials at a controlled temperature and pressure in order to create a billet having predetermined billet characteristics.  
       [0029] In a still further aspect, the invention comprises a screw for use in a plasticator having a barrel, the screw comprising a root and a plurality of threads configured to permit a polyester, other carbocylics and a plurality of reinforcing fibers to be mixed to provide a billet having predetermined billet characteristics without damaging a substantial number of the reinforcing fibers.  
       [0030] It is an object of this invention to provide a system and method for using long reinforcing fibers that can be loaded simultaneously along with the thermoplastics being used.  
       [0031] Another object is to facilitate providing a system and method which is simple and economical and which provides a process that generally preserves the length of the reinforcing fibers through the plasticating and molding process.  
       [0032] Another object of this invention is to provide a method and apparatus which evenly distributes any filler materials, such as reinforcing fibers, which are used in the apparatus and method.  
       [0033] Still another object of the invention is to provide a method and apparatus which facilitates using contaminated molding materials which have heretofore been undesirable for use because of their contamination or because they are expensive to clean sufficiently for use.  
       [0034] Still another object of this invention is to provide a method and apparatus which facilitates or enhances chemical bonding and molecular orientation of the polymer molding materials being used.  
       [0035] Yet another object is to provide a system and method for efficiently and effectively in-molding graphics into a part such as a basketball backboard or other sporting equipment.  
       [0036] In a still further aspect of the invention this invention comprises a plasticating process comprising the steps of loading a plasticator with a plurality of molding materials, creating a mixture with the plurality of molding materials in the plasticator, and plasticating the mixture of said plurality of molding materials at a controlled temperature and pressure in order to create a billet having predetermined billet characteristics.  
       [0037] In another aspect of the invention a process for molding a part comprises the steps of placing a sheet into a mold prior to molding, placing a billet onto the sheet, compression molding the sheet and the billet to produce a part such that the sheet becomes integrally molded with the part.  
       [0038] In another aspect of the invention a molded part comprising a compression molded part molded from a plurality of materials comprising a predetermined amount of a reinforcing fiber and thermoplastic polymers, a sheet integrally molded into said part, the sheet comprising a graphics side facing away from the part.  
       [0039] In still another aspect of the invention a basketball backboard comprising a backboard member molded from a plurality of materials comprising a predetermined amount of a reinforcing fiber and thermoplastic polymers, and a sheet integrally molded into the backboard member, the sheet comprising a graphics side facing away from the part.  
       [0040] These objects and others will be more apparent when the following description is read in conjunction with the claims and drawings. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0041]FIG. 1 is a view of a system according to one embodiment of the invention, comprising a plasticator and a press;  
     [0042]FIG. 2 is a fragmentary view of the plasticator shown in FIG. 1;  
     [0043]FIG. 3 is a fragmentary sectional view showing a screw positioned in a barrel which may be used in the plasticator shown in FIGS. 1 and 2;  
     [0044]FIG. 4 is a view similar to FIG. 3 showing a screw having a plurality of pitch diameters or distances;  
     [0045]FIG. 5 is a sectional view showing the beginning of the plasticating process;  
     [0046]FIG. 6 is a sectional view similar to FIG. 5 showing the screw withdrawing from a passageway in the barrel;  
     [0047]FIG. 7 is another view showing the screw withdrawing further from the passageway in the barrel;  
     [0048]FIG. 8 is a view similar to FIG. 7 showing a knife blade in an open position;  
     [0049]FIG. 9 is a view showing the screw acting as a plunger and forcing the mixed suspension of molding materials out of an extrusion end of the barrel;  
     [0050]FIG. 10 is a view similar to FIG. 9 showing the knife in the closed position, thereby severing the mixed suspension of molding materials to provide a billet;  
     [0051]FIG. 11 is a top view showing a screw drive system in a home position;  
     [0052]FIG. 12 is a view similar to FIG. 11 showing the screw drive system withdrawing the screw from the barrel;  
     [0053]FIG. 13 is another view showing the screw drive system after it has withdrawn the screw further from the barrel;  
     [0054]FIG. 14 is an end view of the plasticator showing a knife assembly used in the plasticator;  
     [0055]FIG. 15 is a view similar to FIG. 14 showing a knife activated to a fully open position; and  
     [0056]FIGS. 16 a  and  16   b,  taken together, are schematic diagrams showing a process according to an embodiment of the invention.  
     [0057]FIG. 17 is an exploded view illustrating a mold for manufacturing a basketball backboard;  
     [0058]FIG. 18 is a front view of the basketball backboard manufactured in accordance with the mold shown in FIG. 17;  
     [0059]FIG. 19 is a fragmentary side view of the basketball backboard shown in FIG. 18;  
     [0060]FIG. 20 is a rear view of the basketball backboard shown in FIG. 18 illustrating various ribs which facilitates strengthening the backboard; and  
     [0061]FIG. 21 is a view of a point-of-purchase display manufactured in accordance with an aspect of this invention. 
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT  
     [0062] Referring now to FIG. 1, a system  10  for molding a part is shown. The system  10  comprises a plasticator  12  for receiving a plurality of molding materials  14  and also for plasticating the molding materials  14  into a billet  16 . The system  10  also comprises a press  18  associated with the plasticator  12  for receiving the billet  16  and for molding the billet  16  into the part (not shown) defined by a mold  20 .  
     [0063] The plasticator  12  comprises a base  22  which supports the various components of the plasticator  12 . The base  22  has a support column  24  which supports a stationery block  26 . The plasticator  12  comprises a suspender or barrel  28  having a feeding end  28   a  mounted to the stationery block  26 . The plasticator  12  also comprises a screw  30  (FIG. 3) which is rotatable and axially mounted in barrel  28  as described below.  
     [0064] The system  10  comprises a controller/micro-processor  32  for controlling the operation of the plasticator  12  and press  18 . The controller  32  includes an operator control box  34  for interfacing with controller  32 . A suitable controller is the Model Slick 150 manufactured by Allen Bradley of Fairfield, N.J., but it should be understood that any suitable controller which is capable of controlling the operation of the system may be used.  
     [0065] As best illustrated in FIG. 1, the plasticator  12  further comprises feeding means or a feed hopper  36  having an opening  38  for receiving the molding materials  14 . The feed hopper opening  38  may be directly connected to a supply system (not shown) for moving materials from a storage or drying area (not shown) to the system  10 .  
     [0066] The feed hopper  36  may include an agitator  40  (FIG. 2) for facilitating agitating and mixing the molding materials  14 . The agitator  40  is coupled to a drive motor  42  which in turn is coupled to a control box  44  which controls the speed and operation of the drive motor  42 . In one embodiment, the control box  44  is coupled to controller  32 , thereby permitting the controller  32  to control the operation of the drive motor  42 . The drive motor is an electric drive motor, but it could be any suitable type of motor for driving the agitator, such as a hydraulic or pneumatic motor.  
     [0067] The feed hopper  36  has an end  36   a  coupled to stationery block  26  so that the molding materials  14  may be fed into a feeding opening  46  (FIG. 3) in the feeding end  28   a  of barrel  28 .  
     [0068] The feeding means or feed hopper  36  may comprise a preheater  48  (FIG. 1) which is coupled to controller  32  for preheating the molding materials  14  to a preheated temperature before the molding materials  14  are introduced into the feeding opening  46  in barrel  28 . In the embodiment being described, the preheater  48  may preheat the molding materials  14  in feed hopper  36  to between 100 and 300 degrees Fahrenheit, depending on the molding materials  14  selected and used. Although not shown, the feed hopper  36  may be insulated to facilitate maintaining the temperature in the feed hopper at the preheated temperature.  
     [0069] The suspender or barrel  28  has a feeding end  28   a  and also an extruding end  28   b  from which billet  16  is extruded. In one embodiment, the barrel  28  is approximately four feet long and has an outside diameter of approximately eight inches and an inside diameter of approximately four inches. The barrel  28  is manufactured from hardened steel and weighs approximately 300 pounds. The barrel may have a die  50  located at the extruding end  28   b.  The function of the die  50  is to cause the billet  16  to be extruded into a predetermined shape or diameter. For example, the billet  16  may be extruded so that its cross-sectional diameter is approximately 2.0 inches.  
     [0070] As illustrated in FIGS.  3 - 10 , the barrel  28  comprises a feeding portion  54 , a blending portion  56  and an extruding portion  58 . The plasticator  12  also comprises the screw  30  which is rotatively and axially mounted in a passageway  52  defined by barrel  28 . Notice that screw  30  comprises a feeding end  30   a  and an extruding end  30   b.  The screw  30  further comprises a feeding section  60  associated with the feeding end  30   a,  a blending section  62 , and an extruding section  64  associated with extruding end  28   b.  The feeding section  60 , blending section  62  and extruding section  64  of screw  30  become generally associated with the feeding portion  54 , blending portion  56  and extruding portion  58 , respectively, of barrel  28  when the screw  30  is located in a home position generally shown in FIGS.  3 - 5 .  
     [0071] The feeding section  60  comprises a first plurality of threads  66 . The blending section  62  comprises a second plurality of threads  68 , and the extruding section  64  comprises a third plurality of threads  70 .  
     [0072] As illustrated in FIG. 3, the first plurality of threads  66  have a depth, identified by double arrow  72 , which is generally greater than the depth, identified by double arrow  74 , of the second plurality of threads  68  associated with the blending section  62  of screw  30 . The first and second plurality of threads  66  and  68  may have a depth which is greater than the depth  76  of the third plurality of threads  70  associated with extruding section  64 . It is to be noted that screw  30  comprises a shaft or a root or core  30   d  about which the first, second and third plurality of threads  66 ,  68  and  70  are located. As best illustrated in FIGS. 2 and 3, the core  30   d  may be generally tapered to provide a screw depth that generally decreases from the feeding end  30   a  to the extruding end  30   b.  This facilitates ensuring that the depth  72  of the first plurality of threads  66  is generally greater than the depth  74  of the third plurality of threads  70 .  
     [0073] Another embodiment of the screw  30  is shown in FIG. 4. In this embodiment, the second plurality of threads  68  are provided with a greater number of threads (i. e., a smaller pitch or distance between threads) than the first plurality of threads  66 . The embodiments shown in FIGS. 3 and 4 facilitate controlling the mixture and suspension time of the molding materials  14  and, further, mixing the molding materials  14  with a predetermined pressure and shear, without significantly damaging the molding materials  14  as the screw  30  rotates.  
     [0074] In one embodiment the screw  30  is approximately 100 inches long and has a core  30   d  diameter of approximately 3.7 inches. The screw  30  is a left-hand screw, and the depths  72 , 74  and  76  are 0.8 inch, 0.6 inch, and 0.75 inch, respectively. The blending section  62  of screw  30  has about 30% more turns in FIG. 4 when compared to the feeding section  60 .  
     [0075] The plasticator  12  also comprises means for driving screw  30  or a screw drive system  75  for rotatably and axially driving the screw  30  in a passageway  52  (FIG. 3) of barrel  28 . The screw drive system  75  is capable of controlling the rotational and axial movement of screw  30  in the barrel  28  in order to facilitate mixing the molding materials  14  into a molten suspension and ultimately, into billet  16  having certain predetermined characteristics. When the mixed molten suspension achieves the predetermined characteristics, such as a predetermined volume, density, viscosity, or size as indicated by predetermined temperature and pressure, then screw  30  is allowed to withdraw in the direction of arrow  77  in FIG. 3 to permit the suspension to be formed into the billet  16  at a storage or extruding area  124  of barrel  28 . As described below, the screw drive system  75  is also capable of controlling the rotational speed of screw  30  and the axial movement of screw  30  until the desired predetermined characteristics are achieved.  
     [0076] The screw drive system  75  (FIG. 2) comprises means coupled to screw  30  for rotatably driving screw  30  and also for axially driving screw  30  into and out of passageway  52  (FIG. 2) in barrel  28 . The means comprises a slidable block  78  which is slidably mounted on a pair of stationary column supports  80  and  82 , each having an end (such as  92   a ) secured to stationary block  26 . The means also comprises suitable bearings (not shown) located in slidable block  78  for facilitating the axial movement of slidable block  78  in the direction of double arrow  84  in FIG. 2.  
     [0077] The screw drive system  75  also comprises a block driver  86  for slidably driving the slidable block  78  in the direction of double arrow  84 . In the embodiment being described, the block driver  86  comprises a pair of push/pull hydraulic cylinders  88  and  90  (FIGS.  11 - 13 ). The screw drive system  75  also comprises a drive motor  92  which is coupled to screw  30  and which rotatably drives screw  30  in either a clockwise or counterclockwise direction as desired. In the embodiment being described, the drive motor  92  is a hydraulic motor which is capable of rotating screw  30  at approximately 0 to 100 rpms.  
     [0078] The screw drive system  75  may comprise first sensing means or sensor  94  for sensing the rpms of drive motor  92 . First sensing means  94  may also include a torque sensor (not shown) which is coupled to controller  32  and which monitors or senses the torque of screw  30  as it produces the billet  16 .  
     [0079] The plasticator  12  comprises power means or a power system  96  for energizing drive motor  92  and block driver  86 . In the embodiment being described, the power system  96  comprises an electric motor  98  which drives a hydraulic pump  100 . The hydraulic pump  100  pumps oil from a reservoir  102  through filter  104  into control means or control block  106 . The control block  106  comprises pressure valves  108 ,  110 ,  112 ,  114  and  116  which control the delivery of fluid to cylinders  88 ,  90 , drive motor  92  and to a knife driver  118  as described below. The pressure valves  108 ,  110 ,  112 ,  114  and  116  are coupled to controller  32  which is capable of controlling their operation as described below.  
     [0080] The power system  96  may comprise a plurality of variable pressure regulators, such as regulator  117 , which may be positioned between the drive motor  92 , cylinders  88  and  90  and their respective pressure valves in order to facilitate controlling the hydraulic pressure delivered thereto. For example, the pressure regulator associated with the cylinders  88  and  90  can be adjusted so that the pressure delivered to cylinders  88  and  90  can be varied. One suitable pressure regulator is the Vickers regulator, manufactured by Vickers of Troy, Mich. This permits an operator to vary the amount of pressure at which the slidable block  78  is biased towards the stationary block  26 .  
     [0081] As the screw drive system  75  drives and forces molding materials  14  into a storage area  124  (FIG. 3) associated with the extruding portion  58  of barrel  28 , the pressure in the barrel  28  begins to build. Such pressure increases as more of the molten suspension of molding materials  14  are forced and driven into the storage area  124 . When such pressure reaches or exceeds the predetermined pressure being delivered to cylinders  88  and  90 , the pressure causes screw  30  to withdraw from passageway  52  as shown in FIGS.  3 - 5 . Consequently, by controlling the pressure delivered to cylinders  88  and  90 , the density, volume and viscosity of the molten suspension and the billet  16  can be accurately controlled. By adjusting the pressure delivered to cylinders  88  and  90 , the viscosity, volume and density of the molten suspension and billet  16  can be made to conform to the desired material characteristics and controlled. Although not shown, other types of regulators may be used. For example, electronic or pneumatic regulators may be provided which is coupled to controller  32  for automatically adjusting the pressure delivered to cylinders  88  and  90  and drive motor  92 .  
     [0082] As best illustrated in FIG. 2, the system  10  also comprises sensing means or a second sensor for sensing the pressure in the power system  96 . In the embodiment being described, the sensing means comprises a pressure gauge  126  for measuring the pressure being delivered by the hydraulic pump  100 . In addition, sensing means also comprise pressure gauge  128  for sensing the pressure being delivered to cylinders  88  and  90 . Although not shown, it should be appreciated that sensing means could comprise any suitable hydraulic, electronic or other suitable means which are capable of sensing the pressure being delivered by control block  106  to drive motor  92 , knife driver  118 , and cylinders  88  and  90 .  
     [0083] The plasticator  10  also comprises an adjustable distance sensor  130  which senses the travel distance of screw  30  as it withdraws from the passageway  52  of barrel  28 . When the actual travel distance reaches a preset distance, the distance sensor  130  generates a distance signal which is received by controller  32 . Upon receipt of the distance signal, controller  32  energizes pressure valves  108 ,  110 ,  114  and  116  to shut the fluid pressure being delivered to cylinders  88 ,  90  and drive motor  92 . As described later herein, controller  32  may then energize pressure valve  112  to deliver fluid to knife driver  118  in order to drive knife blade  120  into the open position shown in FIGS. 9 and 15. Controller  32  may then energize control block  106  and pressure value  108  to actuate hydraulic cylinders to pull or slidably drive slidable block  78  towards stationary block  26  which causes the molten suspension to be extruded out of extruding opening  132  (FIG. 9) associated with the extruding end  28   b  of barrel  28 . Controller  32  may then energize knife driver  118  to force knife blade back into the closed position shown in FIGS. 10 and 14 thereby severing the molten suspension to provide billet  16 .  
     [0084] It should be noted that the distance sensor  134  comprises a bracket  136  which has an end  136   a  secured to slidable block  78 . The distance sensor  134  also has a switch  138  secured to the bracket  136 . A plurality of contact switches are slidably mounted on a panel  148  (FIG. 1) which is secured to stationary block  26 . The panel  148  has distance indicia thereon, and the contact switches  140  can be slidably adjusted on the panel  148  to generally correspond to the volume of the billet  16  to be extruded from barrel  28 . Thus, as slidable block  78  moves in the direction of arrow  122  and thereby causes screw  30  to withdraw from passageway  52 , contact switch  140 , for example, contacts switch  138 , thereby generating the distance signal which is received by controller  32 . Although not shown, it should be appreciated that the distance sensor could be any suitable means for measuring the size, including volume, of the billet  16  which is being created. For example, other suitable electrical, optical, hydraulic, pneumatic, or other types of sensors may be employed for measuring the distance the screw  30  and block  78  travels.  
     [0085] The system  10  comprises heating means or a heater for plasticating the molding material  14  using a single thermal cycle from introduction of materials  14  to molding a part or product from billet  16 . As illustrated in FIGS. 1 and 2, the plasticator  10  comprises heating means or a heater system,  150 , in the embodiment being described, which comprises three sets of resistance or heating bands  152 ,  154  and  156 . The heating bands  152 ,  154  and  156  on the barrel  28  are associated with the feeding portion  54 , blending portion  56  and extruding portion  58 , respectively, as illustrated in FIGS.  3 - 5 . The heating bands  152  heat the feeding portion  54  to a first predetermined temperature. Likewise, the heating bands  154  heat the blending portion  56  to a second predetermined temperature, and the heating bands  156  heat the extruding portion  58  to a third predetermined temperature.  
     [0086] The heating bands  152 ,  154  and  156  are coupled to heater controller  158  which is capable of energizing the heating bands  152 ,  154  and  156  to heat barrel  28  the first, second and third predetermined temperatures, respectively. The heater controller  158  comprises a third sensing means or a third sensor for sensing the actual temperature of the feeding portion  54 , blending portion  56  and extruding portion  58 , respectively, of barrel  28 . The heater controller  158  also comprises display means or a display consisting of displays  160  (FIG. 2) for displaying the actual temperature sensed by heater controller  158 . The heater controller  158  is coupled to controller  32  which may also control the operation of heater  150  in heating bands  152 ,  154  and  156 . In the embodiment being described, the first predetermined temperature associated with the feeding portion  54  ranges from 300 to 500 degrees Fahrenheit, depending on the molding materials  14  being used. Likewise, the second and third predetermined temperatures may also range from 300 to 500 degrees Fahrenheit. Although these ranges are shown, they are not meant to be limiting and other ranges may be appropriate, depending upon the molding materials  14  and desired or predetermined billet characteristics being used.  
     [0087] Although not shown, the barrel  28  and heating bands  152 ,  154  and  156  may be insulated to facilitate minimizing heat loss in barrel  28 .  
     [0088] The heating means may also include the preheater  48 , a knife blade heater, and a mold heater  182 , to facilitate providing one thermal rise. In the embodiment being described, the mold heater  182  may comprise Model Nos. S-8412 or 3412 Sterl-Tronic Temperature Control manufactured by Sterl Co. of Milwaukee, Wis. Furthermore, a screw heater (not shown) may also be provided to heat screw  30  to further facilitate heating the molding materials  14  in barrel  28 .  
     [0089] The plasticator  12  also comprises a separator or knife assembly  162  (FIGS. 14 and 15) for separating the molding materials  14  to provide the billet  16 . The knife assembly  162  is associated with the extruding ends  28   b  of barrel  28  and comprises a pair of L-shaped mounting brackets  164  and  166  which define a channel  168 . The knife assembly  162  also comprises the knife blade or knife  120  which is slidable mounted in channel  168 . The knife blade  120  is coupled to knife driver  118  which is capable of driving the knife from the closed position in FIG. 14 to the open position in FIG. 15 and vice versa. The knife driver  118  comprises a push/pull type cylinder in the embodiment being described which is coupled to pressure valve  112  which in turn is coupled to controller  32  as mentioned previously herein.  
     [0090] The knife assembly  162  comprises a pair of switches  170  and  172  which cooperate with a trigger bar  174  located on knife blade  120 . The trigger  174  triggers switch  170  to generate a closed signal when the knife  120  is in the closed position. Likewise, the trigger  174  causes switch  172  to generate an open signal when the knife  120  is in the open position. The switches  170  and  172  are coupled to controller  32  which receive the open and closed signals.  
     [0091] It should be appreciated that due to the proximal location of the knife  120  to the extruding end  28   b  of barrel  28  and die  50 , the knife  120  becomes heated to approximately the same temperature as the extruding portion  58  of barrel  28 . Note also that when the knife  120  is in the closed position, it seals the passageway  52  (FIGS. 3 and 4) of barrel  28  so that the molded suspension of molding materials  14  can be forced against the barrel side  120   a  (FIG. 3) of knife  120 . Although not shown, the knife  120  may also be provided with the knife heater mentioned above which would be coupled to controller  32  to facilitate heating the knife  120  to a predetermined knife blade temperature which would generally correspond to the third predetermined temperature.  
     [0092] The system  10  comprises press  18  (FIG. 1) which comprises a press driver  176  which is coupled to a press controller  178  which may also be coupled to controller  32 . The press controller  178  may energize press driver  176  to drive platform  180  from an open or non-molding position shown in FIG. 1 to a closed or molding position (not shown). As illustrated in FIG. 1, platform  180  may have a mold member  20   a  which cooperates or mates with a complementary mold member  20   b  to mold the part. In the embodiment being described, the press  18  is a compression press like the 250 ton Bipel Press, manufactured by Bipel of England, and the press controller  178  may be a controller provided by Allen Bradley which may be coupled to controller  32 .  
     [0093] The press  18  also comprises the press heater  182  mentioned above which is coupled to press controller  178  and which is capable of controlling the temperature of the mold members  20   a  and  20   b  when they are molding the part. In the embodiment being described, the mold heater  182  can vary the temperature of the mold members  20   a  and  20   b  from approximately 30□ F to 350□ F depending on the molding materials  14  being used. It is to be noted that the press  18  is a compression press which includes a pressure regulator  184  for regulating the pressure delivered to the billet  16 . In the embodiment being described, the pressure can vary from 0 psi to 4000 psi. The press  18  also comprises a pressure gauge  186  and timer  188  for displaying the pressure and mold time, respectively, during corresponding operation of the press  18 .  
     [0094] The system  10  also comprises conveyance means or a conveyance system  190  (FIG. 1). The function of the conveyance system  190  is to position billet  16  in mold member  20   b  after billet  16  is extruded from the extruding end  28   b  of barrel  28 . In this regard, the conveyance system  190  may be any suitable means for conveying the billet  16  directly into the press  18 , such as robotic arm, a hydraulic cylinder, a pneumatic cylinder, an electronic or mechanical conveyor or any other suitable means for causing billet  16  to be positioned in press  18 . Furthermore, the conveyance system  190  may also comprise means for conveying or positioning the plasticator  12  in operative relationship with the mold member  20   b  such that when the billet  16  is extruded from barrel  28 , it drops directly onto mold member  20   b.  In this regard, the conveyance system  190  may comprise a wheel, shuttle and track arrangement (not shown) onto which the plasticator  12  may be positioned such that the plasticator  12  may be slidably moved towards and away from press  18 . For example, the shuttle and track system would be coupled to controller  32  so that when the press  18  moves to the open position shown in FIG. 1, the extruding end  28   b  of barrel  28  is moved into operative relationship underneath platform  180 , such that when the billet  16  is extruded, it becomes positioned on mold member  20   b  as shown in FIG. 1. The plasticator  12  may then be moved or shuttled away from press  18  and the platform  180  driven downward (as viewed in FIG. 1) to mold the part. After the part is molded, it may be removed from the press  18  and, during such removal, the plasticator  12  may again be shuttled or moved to extrude the next billet  16  onto mold member  20   b.  Other variations of moving the plasticator  12  may also be used. For example, the conveyance system  190  may cause the plasticator  12  to withdraw from press  18  slowly so that the billet  16  is extruded substantially evenly over the length of the mold member  20   b  when the billet  16  is placed in the mold.  
     [0095] The molding materials  14  are preferably comprised of a polyester  192 , a carbocyclic or other carbocylics  194  and a preselected filler  196  (FIGS. 1, 16 a  and  16   b ). In the embodiment being described, the polyester  192  may include polyethylene terephthalate (PET), and the carbocylics  194  may be an olefinic such as polycarbonate, polypropylene (PP), polyethylene (PE) or ethylene vinyl acetate (EVA).  
     [0096] The preselected reinforcement or filler  196  may comprise a reinforcing fiber, glass fiber, fly ash, clay, carbon or graphite fiber, shredded reinforced fiber composite material, or like materials. It has been found that this apparatus and method can use fibers introduced to plasticator  12  with the other molding materials  14 , without the fibers incurring significant damage. It should be appreciated, however, that this apparatus and system could be used with reinforced fibers, such as glass fibers, which range from the smallest available to as long as 6 inches.  
     [0097] A compatibility enhancing agent or agents  198  may also be included as one of the molding materials  14  which is added into feed hopper  36 . It should be appreciated that the polyesters  192 , carbocylics  194 , preselected fillers  196  and compatibility enhancing agents  198  may take any suitable form which is capable of being received in the feed hopper  24 , such as the form of chips, pellets, flakes and fibers. In addition, reinforcing fiber may take the form of single strands, shavings, mats, edge trimmings or shreddings as may be contained in shredded or reground reinforced composites containing such fibers in an existing polymer matrix. In other words, an existing thermoplastic polymer matrix having one or more of the above molding materials  14  may be, for example, shredded and used.  
     [0098] The compatibility enhancing agent or agents  198  are heat activated and are chosen so as to enhance the compatibility of the thermoplastic polymers, such as glass or glass fibers, and any other reinforcements or fillers which may be added. For example, olefinic polymers grafted with polar functional moieties such as acrylic acid or maleic anhydride may be mentioned. In this regard, the “Polybond” products available from BP Chemicals are presently preferred for use.  
     [0099] Preliminary studies have indicated that “Polybond” product grades 1000, 1001, 1002 and 1003 are suitable compatibility enhancing agents  198  that may be added to the thermoplastic polymers and fillers  196 . These particular “Polybond” products are polypropylene based coupling agents grafted with CA. 6% acrylic acid. The only difference between these 4 grades of “Polybond” materials is in the melt flow rate “mfr”. These range from 100 g/10 min. (“Polybond” 1000) to 12 g/10 min. (“Polybond” 1003). The skilled artisan can choose the particular desired mfr based upon the identity of the materials fed to the plasticator  12  and the initial processing viscosity thereof desired. Other exemplary compatibility enhancing agents  198  include “Polybond 1009 and 3009”, both available from BP Chemicals. These polymers can be described as having high density polyethylene backbones grafted with either acrylic acid or maleic anhydride. The 1009 product is grafted with CA. 6% acrylic acid having a melt index of 6 g/10 min. while “Polybond” 3009 is grafted with about 2% maleic anhydride and has a melt index of about 6 g./10 min.  
     [0100] Other “Polybond” products can also be mentioned as being exemplary. These include the polypropylene based polymers grafted with varying amounts of maleic anhydride. For example, “Polybond” 3001 is described as a polypropylene polymer with grafted maleic anhydride branches present at a level of about less than ¼%. This product exhibits a melt flow rate of about 5 g./10 min. “Polybond” 3002 is also exemplary and is similar to the 3001 product except that its maleic anhydride content is about twice as high and that it exhibits a MFR of 7 g./10 min.  
     [0101] Additionally, free radical generating polymerization catalysts such as peroxides may be admixed with ethylenically unsaturated acids or anhydrides and used herein as compatibility enhancing agents.  
     [0102] Other exemplary compatibility enhancing agents include the EPOLENE polymers available from Eastman Chemical and other experimental nucleating agents also available from Eastman and that are specifically formulated for polyester rather than olefins. EPOLENE is a trademark of Eastman Chemical.  
     [0103] The compatibility enhancing agent  198  which are normally fed to the feed hopper  36  in an amount of 1 to 10 (% by weight) based upon the weight of the thermoplastic polymeric material used.  
     [0104] An advantage of the system  10  is that it is capable of handling post consumer molding materials or molding materials which have a relatively high degree of contamination. For example, the molding materials  14  may be commingled or contaminated polymeric material as typically found in the post consumer waste stream. While the nature of contaminants and the percent of occurrence varies from lot to lot as a natural feature of waste materials, they do, on average, typically contain similar materials and in similar quantities. For example, post consumer polyesters (collected in the waste stream as PET) used in this process may contain 90% PET, 5% HDPE, 2% PP, 0.5% EVA and the remainder contaminants, including such things as miscellaneous paper and aluminum scrap.  
     [0105] The invention will now be described with reference to a number of specific examples which are to be regarded solely as illustrative and not as restricting the scope of the invention.  
     EXAMPLE 1  
     [0106] First, molding materials were used without the compatibility enhancing agent  198 . Sixty (60) parts of a mixed post consumer polymer batch comprising PET, HDPE, PP and ethylene vinyl acetate (EVA) and 40 parts of scrap (landfill destined) glass fiber edge trimmings having nominal 2 inch fiber lengths were charged to the single reciprocating screw plasticizer shown in FIG. 1. Compounding the billet  16  occurred in a single thermodynamic cycle with a temperature rise to 430 degrees Fahrenheit for a period of 30 seconds, at which time the resulting mixed and molten bulk molding billet  16  was delivered to the press where a 6″×9″ sample, 0.150 inch thick, was molded at a pressure of 3000 psi. The molded billet  16  was subjected to physical property tests and was found to exhibit a flexural strength of 10,300 psi, a flexural modulus of 700,000 psi and a notched IZOD of 0.43. These characteristics are representative of a strong but brittle material considered to have minimum desirability in product fabrication.  
     EXAMPLE 2  
     [0107] A mix of one-half post consumer polyethylene terephthalate (PET) derived from soft drink bottles and one-half shredded scrap from a 40% glass reinforced polypropylene composite material resulting in short chopped glass lengths was charged to the plasticizer  12  shown in FIG. 1. Compounding in the barrel  8  occurred at 500 degrees Fahrenheit to 550 degrees Fahrenheit for a time period of 60 seconds. The sample was tested and exhibited an average 12,500 psi flexural strength, a 435,000 psi flexural modulus, and a notched IZOD of 5.7 ft.-lbs./inch. This represents a material with performance satisfactory for a wide range of product uses.  
     EXAMPLE 3  
     [0108] Another example includes the use of the compatibility enhancing agent  198 . Sixty (60) parts of a mixed (commingled and contaminated) post consumer polymer batch and 40 parts of scrap (landfill destined) glass fiber edge trimmings with nominal 2″ fiber lengths were charged to the plasticizer  12  shown in FIG. 1. The polymer material was primarily PET, but also contained polycarbonate, HDPE, polypropylene, EVA and non-polymer material such as scrap from aluminum cans and paper. A compatibility enhancing agent  198  (Polybond 3009) was added to the mix in the plasticizer  12  at a ratio of 3% by weight based upon the weight of polymeric material fed. The first, second and third predetermined temperatures were set at 490 degrees Fahrenheit, 520 degrees Fahrenheit, 530 degrees Fahrenheit, respectively, in the feeding plasticating area, and 540 degrees Fahrenheit in the delivery area. The knife head  96  was set to 550 degrees Fahrenheit. The distance sensor was set a 110 mm. The plasticizer  12  was operated with a screw speed of 20-40 rpm and cylinders  88  and  90  were set at 300 psi such that pressure of 50 psi building to 300 psi resulted in the reciprocating screw  42  being pushed by barrel back pressure to the 110 mm position. At this time (after about three total minutes from introduction of materials to the plasticizer  12 ), a mixed and molten billet  16  was then delivered to the press  18  with mold faces  20   a  and  20   b  thereof heated to 80 degrees Fahrenheit. A 6″×9″ sample, 0.150 inch thick, was then molded at a pressure of 3,000 psi. The sample was tested and exhibited a flexural strength of 20,310 psi, a flexural modulus of 980,000 and a notched IZOD of 3.03 ft.-lbs./inch. This material would be suitable for a wide range of product applications having strength and modulus properties analogous to commercially available and widely used glass reinforced thermoplastic sheet materials.  
     [0109] A method and process for using system  10  and for creating in billet  16  for molding a part will now be described. First, a post-consumer recyclable plastic, such as PET, polypropylene, polyethylene and ethylene vinyl acetate are collected as shown at step  200 . If desired, these recyclable polymers may be separated (for example) by flotation separation (as shown in block  202 ). The contaminated polyesters  192  and carbocylics  194  along with the preselected reinforcements and fillers  196  are loaded into feed hopper  36  (FIG. 1) of plasticator  12  as shown in block  204 . As mentioned earlier herein, the compatibility enhancing agent  198  may also be added at this time, if desired.  
     [0110] It may be desirable to preheat the molding materials (block  206 ), in which case controller  30  energizes preheater  48  to preheat the molding materials  14  (block  208 ) to approximately 100□ to 350□ F, depending on the molding materials  14  selected. Controller  32  then energizes drive motor  42  to rotatably drive agitator  40  to begin mixing the molding materials  14  in feed hopper  36 .  
     [0111] At block  210  a billet  16  is plasticized. Depending upon the part being molded, the predetermined characteristics of billet  16  are determined. Thus, the volume, density and length, for example, of billet  16  are determined. Once determined, the variable pressure regulator  117  associated with cylinders  88  and  90  is adjusted to a pressure which generally corresponds to the billet characteristics selected. In addition, one or more of the contact switches  140  of distance sensor  134  are adjusted to correspond to the length and volume of the billet  16  desired. In addition, the variable pressure regulator  117  associated with drive motor  92  is also adjusted so that drive motor  92  drives screw  32  at an appropriate rpm. The controller  32  is also programmed with the first, second and third predetermined temperatures so that heating controller  158  energizes the plurality of heaters  152 ,  154  and  156  to heat the feeding, blending and extruding portions  54 ,  56  and  58  to the appropriate temperature. For purposes of illustration only, it will be assumed that the pressure regulator  117  was set at 300 psi, the power system  96  pressure was set at 1000 psi, and the pressure regulator associated with drive motor  92  was set at 25 rpm, with contact switch  140  being set at approximately 110 millimeters.  
     [0112] The molding materials  14  are then introduced to the feeding opening  46  (FIG. 5). As best illustrated in FIGS.  4 - 10 , controller  32  energizes drive motor  92  of screw drive system  75  to rotatably drive screw  30  such that the molding materials  14  are gradually blended together into a mixed molten suspension period.  
     [0113] The molding materials  14  are heated to approximately the first predetermined temperature when they are introduced between feeding portion  54  of barrel  28  and feeding section  60  of screw  30 . Note that, due to depth  72  (FIG. 3) and pitch of the flights of the first plurality of threads  66 , the molding materials  14  start to become blended such that the reinforcing fibers, like glass fibers, are not damaged. As screw  30  rotates in the direction of arrow  31  in FIG. 5, the molding materials  14  are forced from the feeding section  60  of screw  30  to the blending section  62  which is associated with blending portion  56  of barrel  28  when the screw  30  is in the home position shown in FIGS. 3 and 4. Notice also that because of the taper of the core  30   a  of screw  30 , the molding materials  14  become blended into a more homogeneous suspension at the blending section  62  where the suspension is heated to approximately the second predetermined temperature mentioned earlier herein. To further facilitate the mixing and blending of the molding materials  14 , the screw  30  may be provided with a blending section  62  having a second plurality of threads  68  (FIG. 4) with a pitch which is generally smaller than the pitch of the first plurality of threads  66 . Varying the number of threads per inch, pitch of threads and thread depth facilitates accurately controlling the suspension and blending time of the molding materials  14 , controlling the volume and density of billet  16 , and controlling the velocity at which the molding materials  14  are plasticated.  
     [0114] As the screw drive system  75  continues to drive screw  30  as mentioned above, the mixed suspension is forced toward the storage area  124  associated with the extruding portion  58  of barrel  28 . In the storage area  124 , the molten suspension is collected, further blended and heated to approximately the third predetermined temperature. The mixed molten suspension ultimately engages the side  120   a  (FIG. 5) of knife  120  and begins forming billet  16  as shown in FIG. 6. As the molten suspension continues to collect in storage area  124 , the pressure begins to build.  
     [0115] As the pressure approaches or exceeds 300 psi (i. e., the pressure applied to cylinders  88  and  90 ) the biasing pressure of cylinders  88  and  90  is overcome and the screw  30  begins withdrawing from passageway  52 , thereby causing slidable block  78  to move in the direction of arrow  122  (FIG. 1). As shown in FIGS.  6 - 8 , the molten suspension begins building in the storage area  124 . The slidable block  78  moves in the direction of arrow  122  until contact switch  140  contacts switch  138  to generate the distance signal which is received by controller  32 . Controller  32  then energizes pressure valves  114  and  116  to stop drive motor  92 . Controller  32  also energizes pressure valve  110  to energize knife drive  118  to cause knife blade  120  to move from the closed position (FIGS. 8 and 14) to an open position (FIGS. 9 and 15). Controller  32  then energizes pressure valves  108  and  110  to actuate cylinders  88  and  90  to pull slidable block  78  in a direction opposite arrow  122 , thereby causing the molten suspension to be extruded through extruding opening  132  (FIGS. 9 and 15). Controller  32  may then energize pressure valve  112  to actuate knife driver  118  to force knife blade  120  into the closed position, thereby separating the molten suspension to provide billet  16 .  
     [0116] Although not shown, it should be appreciated that the controller  32  may cause the screw drive  75  and knife assembly  162  to provide a plurality of billets  16  during a single stroke length of the cylinders  88  and  90 .  
     [0117] The billet  16  may then be conveyed (block  212  in FIG. 16) to mold member  20   b  in press  18  by the conveyance system  190  (FIG. 1). Other materials, such as sheet coating material or reinforcement material may be prepositioned (block  211 ) in the lower mold member  20   b  prior to introducing billet  16  into the mold member  20   b.  Once located in the press  18 , controller  32  may energize press controller to, in turn, energize press driver  176  to drive platform  180  downward (as viewed in FIG. 1) to cause the part to be molded. In the example being described, the mold heater  182  heats the molding members  20   a  and  20   b  to approximately 80 degrees Fahrenheit. In addition, the press  18  is set to compress billet  16  at approximately 3000 psi with a controlled pressure gradient.  
     [0118] At block  214  (FIG. 16 b ), the part is then molded by press  18 .  
     [0119] As shown in decision block  216 , it may be desirable to perform a second operation on the part before it is removed from the press  18  or when the billet  16  is molded. If such an operation is desired, it is conducted (block  218 ) and then the part is removed from the press  18  (block  220 ). In this regard, a second operation may comprise painting or otherwise placing a coating on the part, hot stamping a decal on the part, partially assembling the part, or molding or embossing a symbol on the part. If a second operation is not performed on the part, the part is removed from the press  18  at block  222 .  
     [0120] Note that it may be desirable to integrally mold a surface texture or finish to the part during the molding process. For example, a plastic sheet or film, such as the Teslin sheet, manufactured by PPG Industries of Pittsburgh, Pa., may be integrally molded into the surface of the part. For example, if the plastic sheet was selected, it would be cut to the dimensions of the mold and placed in the mold prior to molding. The side of the sheet which contacts the mold may be coated with an acrylic finish to prevent the sheet from adhering to the mold during the molding process. After the sheet is placed in the mold, the billet  16  can be placed on the sheet and the part molded as described. If desired, a sheet could be placed on both mold members  20   a  and  20   b  before billet  16  is placed on mold member  20   a.  The billet  16  would then be placed on the sheet and molded as described above. This facilitates producing a part having a desired surface texture or finish on both sides. It is to be noted that, after the molding process, the polymer sheet is integral with the part.  
     [0121] It should be appreciated that other types of materials may be integrally molded into the part or into the surface of the part. For example, wood veneer sheets, burlap, or metal wire mesh may be molded into the part or into the surface of the part.  
     [0122] Returning to block  224  in FIG. 16 b,  once the molding process is completed and the part is removed from the press, the process can be repeated for another part. At block  226 , subsequent operations, such as additional graphics, sheet material or printing, assembly, packaging and the like may be performed on the part.  
     [0123] Advantageously, this invention provides a system and method for using relatively highly contaminated post-consumer polyesters and carbocylics (such as olefinics). The system and method also facilitates evenly mixing reinforced fibers having a length of 2.0 inches or more, without damaging the fibers during the compounding, plasticating, extrusion and compression molding process.  
     [0124] Such post-consumer scrap would normally require additional cleaning and separation before use. This invention provides an apparatus and process for using the contaminated post-consumer materials to produce a part which has physical, chemical and mechanical properties similar to non-recycled materials.  
     [0125] Further, the method and apparatus provides a system for molding the molding materials  14  into a part using only a single thermal heat rise by controlling, coordinating and sequencing the temperature rise of the molding materials  14  as they go through the system  10 . Using the single thermal heat rise facilitates enhancing the molecular orientation of the polymers which, in turn, causes the resultant part to have enhanced strength characteristics when compared to other types of molding processes. Also, a single heat rise facilitates reducing the material degradation that occurs to thermoplastic materials when they are heated. Further, because the pressures in the press  18  are adjustable, the surface texture or finish or the resultant part can be controlled to enhance the aesthetic or functional appeal of the part.  
     [0126] The invention also provides a method and apparatus which is advantageous because it reduces or eliminates many of the intermediate handling and thermocycles from receipt of the post-consumer materials to the molding of the part.  
     [0127] The described method and apparatus may utilize compatibility enhancing agent  198  which promote chemical bonding, for example, by increasing the presence of hydroxyl groups and the reinforcing fibers while they aid in the dispersion of reinforcement within the molten suspension.  
     [0128] Finally, molecular orientation within the billet  16  is enhanced by controlling the compression pressures and temperatures in press  18 .  
     [0129] Advantageously, it should be appreciated that long fiber length can be maintained by reducing the tortuous nature of the material path existing in many prior art devices and processes. This improvement of the path results from screw thread depths that allow fibers to move intact, allowing the screw to float on a film of molten material between itself and the barrel. The lack of small orifices in delivering the material through the plasticator  12  and the molding process allows forming without constraining the movement of fibers to form the part.  
     [0130] Referring now to FIGS.  17 - 20 , another embodiment is shown illustrating the use of the system and method for molding an item of sporting goods equipment, such as a basketball board  200  (FIG. 18). In this embodiment, the press  18  comprises the upper molding member  20   a ′ and lower molding member  20   b ′ which cooperates to protect the backboard  200  illustrated in FIGS. 18 and 20. Although not shown, the upper molding member  20   a ′ comprises a rib forming section (not shown) for forming a plurality of ribs  202  (FIGS. 19 and 20) which facilitates strengthening the basketball backboard  200  as conventionally known. The lower mold member  20   a ′ comprises a plurality of recess-forming areas  201  for forming angled recesses  207  (FIG. 18) in backboard  200 .  
     [0131] As mentioned earlier herein, the system and method of the present invention causes the resultant part (in this case, the basketball backboard  200 ) to have enhanced strength characteristics when compared to other types of molding processes. This, in turn, facilitates reducing the number of reinforcing or rib members  202  and also facilitates reducing the material and manufacturing costs associated with producing backboard  200  in the manner described herein.  
     [0132] As mentioned earlier, it may be desirable to integrally mold a surface texture or finish to the part during the molding process. In the embodiment being described, a plastic sheet or film  204  (FIG. 17) may be provided comprising a front side  204   a  and a backside  204   b  which becomes molded such that it is an integral part of the backboard  200 . It should be appreciated that the sheet  204  comprises graphics  206  or printed information on the front surface  204   a  which faces outward away from backboard  200 . In this regard, the printing information may comprise a company name, association affiliation, rectangular target, such as target  208  in FIG. 18, or other graphics as may be desired.  
     [0133] In the embodiment being described, the mold member  20   b ′ (FIG. 17) may comprise a plurality of locating pins  210  which cooperate with the plurality of holes or apertures  212  on sheet  204  to facilitate locating the sheet mold member  20   b′.    
     [0134] The lower mold member  20   b ′ may also comprise a plurality of pins  216  which form a plurality of holes  220  (FIG. 18) for mounting backboard  200  onto a frame or pole (not shown) using suitable fasteners, such as bolts and the like. Notice also that locating pins  210  facilitate defining holes  222  (FIG. 20) for attaching a rim (shown in phantom in FIG. 18) using suitable fasteners, such as bolts, screws and the like (not shown).  
     [0135] It should also be appreciated that the mold member  20   b ′ may be textured or roughened in order to facilitate preventing the sheet  204  from moving once it is placed onto mold member  20   b ′ as described below. In this regard, it has been found that sandblasting a surface  214  of mold member  20   b ′ provides enough texture to facilitate preventing the sheet  204  from moving on mold member  20   b ′. Also, an electric charge may be put to the sheet  204  before or after the sheet is placed in the mold. This also facilitates preventing the sheet  204  from moving on mold member  20   b′.    
     [0136] Notice that the lower mold member  20   b ′ may comprise a graphic sheet receiving area  222  (FIG. 17) and a bordering raised area  224 . In this regard, it should be appreciated that the border area  224  facilitates defining a molded border  226  (FIG. 18) having a surface  226   a  (FIG. 19) which is generally co-planer with surface  204   a  of sheet  204  after the sheet  204  is compression molded as described.  
     [0137] In operation, the upper and lower mold members  20   a ′ and  20   b ′ are mounted on press  18  in a manner conventionally known. When it is desired to mold backboard  200 , the sheet  304  is placed onto lower mold member  20   b ′. Next, the conveyance system  190  (FIG. 1) positions billet  16  onto sheet  204  in mold member  20   b ′ after billet  16  is extruded from the extruding end  28   b  of barrel  28  of plasticator  12 . As mentioned earlier herein, other materials, such as sheet coating material or reinforcement material may be preposition (block  211  in FIG. 16) in the lower mold member  20   b ′ prior to introducing billet  16  into the mold member  20   b ′. As also mentioned previously herein, sheet  204  or side  204   b  of sheet  204  which contacts upper mold member  20   a ′ may be coated with a finish to prevent the sheet  204  from adhering to the mold member  20   a ′ during the molding process.  
     [0138] Once the sheet  204  and billet  16  are positioned between mold members  20   a ′ and  20   b ′ as illustrated in FIG. 17, controller  32  may energize press controller  178  to, in turn, energize press driver  176  (FIG. 1) to drive platform  180  downward as viewed in FIG. 1 to cause the part (i.e., the backboard  200 ) to be molded.  
     EXAMPLE 4  
     [0139] An illustration for molding backboard  200  will now be described. First, billet  16  is formed when plasticator  12  is charged with a mixture of about 83% mixed recycled thermoplastic polyolefins mentioned earlier, 1% compatibility enhancing agent, and 16% glass longer than one-quarter inch. The mixture is heated to a temperature of 450 degrees fahrenheit while being blended into the homogeneous billet  16  in the plasticator  12 , and is collected in the plasticator storage area  124  at a pressure of 300 psi.  
     [0140] The backboard mold members  20   a ′ and  20   b ′ in the compression molding press  18  are set to a temperature of about eighty degrees fahrenheit and the mold is prepared for molding the part by properly orienting a printed sheet  204  of the aforementioned Teslin with the printed side  204   a  face down in the mold member  20   b ′. The plasticator  12  is set to deliver about a thirteen pound billet  16  which is transferred by conveyor system  190  to the press  18  and placed atop the Teslin® sheet  204 . The compression molding press  18  is then closed and delivers a pressure of about 2,000 psi for thirty seconds, at which time the pressure reduces to 500 psi for another thirty seconds. The press  18  is then opened and the finished backboard  200  with integrally molded graphic sheet  200  is removed from the press  18 .  
     [0141] It should be appreciated that the upper and lower mold members  20   a ′ and  20   b ′ are at a lower temperature (i.e., about 80 degrees fahrenheit) relative to billet  16  which is relatively much hotter (i.e., on the order of between 300 to 500 degrees). Because of this temperature differential, the molten billet  16  tends to bond quickly to the back surface  204   b  of sheet  204  during the compression molding process. As the molten plastic or billet  16  cools, the graphic sheet  204  becomes integral with backboard  200 . The temperature differential also facilitates melting the Teslin® at a rate such that it cools before melting graphics  206  on surface  204   a.    
     [0142] After the backboard is molded, backboard  200  may subsequently be mounted onto a suitable frame (not shown) which, in turn, is mounted on a pole or other support structure for supporting the backboard  200  above the ground.  
     EXAMPLE 5  
     [0143] In another embodiment of the invention, a process for making point-of-purchase display or sign  300  (FIG. 21). The plasticator  12  is charged with a mixture of 95% mixed recycled thermoplastic polyolefins and 5% glass longer than one-quarter inch. The mixture is heated to a temperature of 450 degrees fahrenheit while being blended into a homogeneous material in the plasticator  12 , and is collected in the plasticator storage area  124  at a pressure of 300 psi. The point of purchase display product mold (not shown), which comprises a shape which complements the shape of the display  300 , is placed in the compression molding press  18  and is set to a temperature of about 80 degrees fahrenheit. The mold is prepared for molding the display  300  by properly orienting a lithographically printed side  302  of a sheet of Teslin® having desired printed information situated face down in the mold. The plasticator  12  is set to deliver a ten ounce billet  16  which is transferred to the mold and placed atop the Teslin® sheet. The compression molding press  18  is then closed and delivers a pressure of 2,000 psi for fifteen seconds at which time the pressure reduces to 500 psi for another twenty-five seconds. The press  18  is then opened and the finished point of display or sign  300  with printed graphic sheet integrally molded therein is removed from the mold.  
     [0144] While the invention has been described with reference to certain specific embodiments, this description is merely illustrative, and is not to be construed as limiting the scope of the invention. Various other modifications and changes may occur to those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.