Abstract: A shaft assembly comprising an elongated member having at least a portion which is hollow, tubular, shell like having an inside surface defining a shaft core and an outside surface defining a shaft functional surface, the shaft core being filled with a hardened, moldable material, and the shaft functional surface having at least one functional feature thereon, which is of hardened, moldable material integrally molded with the hardened, moldable material in the shaft core. In a preferred embodiment the shaft assembly is rotatable and has at least one molding aperture gate extending through the shaft from the inside surface to the outside surface which is filled with hardened, moldable material which connects the hardened material in the shaft core and functional feature.

Abstract: A method of making a dual lumen catheter which is a unitary, elongated, flexible catheter tube that is substantially circular in cross-section. The catheter tube has an outer wall member forming a tube having a proximal end and a distal end portion adapted for insertion within a vein or artery of a patient. The outer wall member defines first and second coaxial lumens that are separated by an inner common support wall which is substantially circular and joins the outer wall. The first lumen extends longitudinally between the opposed distal and proximal ends of the catheter tube and terminates coextensive with the distal end portion of the catheter tube. The second lumen extends longitudinally from the proximal end of the catheter tube and terminates proximal to the distal end portion of the catheter tube. The second lumen is crescent-shaped in cross-section and substantially surrounds the first lumen. The cross-sectional areas of the first and second lumens are approximately equal.

Abstract: Method and apparatus for cooling porous materials whereby first gases are passed through a porous material, such as polyurethane foam, in a first zone at a predetermined flow rate to cool the porous material and to remove volatiles therefrom in a first gas mixture which exits the porous material at a predetermined temperature. The first gas mixture is combined with second gases having a temperature which is lower than that of the first gas mixture to form a second gas mixture having a temperature which is sufficiently low to condense or sublime one or more of the volatiles. Thereafter, the second gas mixture is passed through the porous material to filter the condensed or sublimed volatiles thereon and to further cool the porous material. The flow rate of the heated gases is controlled to provide a controlled uniform cooling of the porous material, and additional filters may be utilized to remove particulate matter from either of the heated gases or the cold gases, or both.

Abstract: A stopper for a rope which is injection molded on the rope. The stopper has a sleeve-like shape and surrounds the rope without play and prevents an axial slippage of the stopper from the rope. A strut is formed as one piece with the stopper and extends radially through the inner diameter of the rope. Also a method of forming a stopper on a rope is included.

Abstract: A nylon cable tie having a head and a strap terminating in a tip is formed in a mold cavity defined between a first mold part combined wish a second mold part by injecting molten nylon material into the mold cavity through an insulated runner system and a gate that converges from the runner system toward the mold cavity and does not have a hot tip adjacent thereto. The mold parts are separated while retaining a portion of the head in a head region in the first mold part and a portion of the tip in a tip region in the second mold part, in order to separate the head from the second mold part, to separate the tip from the first mold part, and to separate a major portion of the strap from the first and second mold parts. The mold parts are further separated while retaining said portion of the head in the head region to thereby remove said portion of the tip from the second mold part. The head is ejected from the head region by protracted ejector pins that penetrate the head region from within the first mold part.

Abstract: A molded article having an embedded bracket, such as a whirlpool tub, the mold and a method of molding the article. The article includes a rigid shell having a non-finish side and a finish side. The non-finish side is coated with a polymeric material. The polymeric material encloses a bracket and distributes the weight of an attached object, such as a whirlpool motor, over adjacent polymeric material. The bracket is affixed to the rigid shell in a spaced relationship and includes a surface for attaching to an object by attachment means such as a blind bolt. The bracket may also be affixed to the rigid shell by supports which are welded to the rigid shell.

Abstract: A method of producing a decorative pattern on a plastic card housing an etronic circuit in an injection molding machine, includes the steps of introducing and positioning a film, which has applied on at least one surface thereof a decorative pattern, in an open cavity of the injection molding machine, closing the cavity so that the film is fixed and clamped in position, after the closing of the cavity, inserting an electronic circuit chip through an aperture into the mold cavity, injecting a support composition for the card into the mold cavity, and after termination of the injection process, removing the gate or any excess material from the periphery of the card, opening the mold cavity and removing the decorated card.

Abstract: A method of encapsulating a semiconductor device permits use of the same mold for various package types. In one form, a mold (34 and 36) has a first cavity (50) in which a first insert (52 and 53) is positioned, the first insert defining a length and a width of a package body which is to be formed in the mold. The first insert in the first cavity also defines a second cavity (54) in which a second insert (56 and 57) is positioned, the second insert defining a thickness of the package body. Plastic is inserted into the mold to form the package body. To form other package types, one or more inserts are replaced instead of using a different mold. In another embodiment, the inserts are adjustable. For example, rather than having to change inserts to form a package with a different thickness, the inserts are adjusted by, for instance, a screw mechanism (66) within the mold or by the addition or removal of shims (60).

Abstract: A multi-cavity injection mold process, for simultaneously injection molding a plurality of multi-layer articles, having a single hot runner manifold system for the sequential supply of first and second molten molding materials to the cavities of the mold with each of the materials being supplied simultaneously to all cavities in equal quantities. The process also uses a core rod for each cavity in which a concavity is provided, adjacent the entry point of the materials into the cavity, to prevent the first injected material in an injection cycle from being washed from the end of the core rod by the second injected material, the use of a buffer of the first injected material in the neck region of the preform to compensate for variations in temperature of the cavities and material being distributed to different parts of the mold and the use of the first part of the metered quantity of the first to be injected material from the next injection cycle to seal the preform at the end of the injection cycle.

Abstract: A method for forming structural injection molded parts includes the steps of positioning a closed-loop cutting blade in surrounding relation to one of a male and female mold which together define a mold cavity corresponding to the shape of a part to be molded, positioning reinforcing material over the female mold, moving the male mold into the female mold to position the reinforcing material in the mold cavity, thereafter moving the cutting blade independently of the mold which it surrounds to trim the reinforcing material, and injecting resin into the mold cavity to produce a structural injection molded part. The cutting blade and the mold which it surrounds are part of and movable with a common die set assembly having a lost motion drive connection between the mold and the cutting blade, such that the trimming step is accomplished by lost motion movement between the mold and the cutting blade after the male and female molds have been mated.

Abstract: A method of manufacturing composite moldings by executing the following steps (a) to (f) by using an injection molding machine provided with a fixed die having a gate which is opened to a cavity forming surface and a movable die which can come into contact with and out of contact with the fixed die:(a) step of setting a desired skin material to a predetermined position of the movable die in a state in which the movable die is sufficiently removed from the fixed die;(b) a first die clamping step in which the movable die is moved toward the fixed die and is stopped at a position where an interval between the movable and fixed dies is equal to a predetermined value of 5 mm or more;(c) step of injecting a fused resin into a cavity;(d) a second die clamping step in which the movable die is stopped at a desired last position;(e) step of cooling for a predetermined time after the second die clamping step;(f) step of removing the movable die from the fixed die and opening the dies and taking out a product.

Abstract: A method for image-transfer molding half portions of a casing body of a magnetic tape cassette in which no portions of an image transfer film are left in the cassette holes. The image transfer film includes a base layer, a peeling layer, a protective layer, an ink layer, and an adhesive layer. A band of the image transfer film is pinched between dies for molding said half portion, with the adhesive layer positioned so as to abut an outer surface of the molded half portion. A pair of pins is placed in the dies in a position where a hole is to be formed in the half portion, with an end of one of the pins having a peripheral edge portion projecting in a direction parallel to the longitudinal axis of the pin and forming a recess receiving the end of the other of said pins with a portion of the image transfer film sandwiched therebetween.