Abstract: An integrated noise suppression acoustic panel includes a back plate, a face plate, and a bulk foam absorber disposed between the back plate and the face plate. The bulk foam absorber is formed of a thermoset material, such as bismaleimide or phenolic, and is manufactured using a low pressure process. In particular, a foamable material is melted, and a blowing agent is mixed with the foamable material to obtain a mixture. The foam is formed and the mixture is cured by heating it to a temperature, and maintaining the mixture at the temperature for a time sufficient to cure the mixture.

Abstract: Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.

Abstract: Continuous polymeric extrusion nucleation systems and methods useful for making polymeric microcellular foamed materials, including crystalline and semi-crystalline polymeric microcellular materials, are provided. Pressure drop rate is an important feature in some embodiments, and the invention provides systems for controlling these and other parameters. One aspect involves a multiple-pathway nucleator that is separated from a shaping die by a residence chamber. Another aspect involves a die for making advantageously thick articles, including a multiple-pathway nucleation section. Microcellular material can be continuously extruded onto wire, resulting in a very thin, essentially closed-cell microcellular insulating coating secured to a wire. Other very thin microcellular products can be fabricated as well.

Abstract: A process for adjusting the level of water or water soluble additives in aqueous-based powder injection molding compounds for the purpose of recycling scrap material, controlling shrinkage or rehydrating dry feedstock. Depending on the objective, the process may require material granulation equipment, equipment for the addition or removal of water and mixing equipment. The molding compounds may be comprised of either recycled scrap material before being heat-treated or dry, virgin feedstock material.

Abstract: A multilayered structural element which is useful for forming housings for electronic devices such as cellular telephones. The multilayered structural element has sequentially attached layers: (a) thin, flexible polymeric outer film layer, (b) an electronic interface layer, the electronic interface layer comprising a thin, flexible polymeric film layer having a pattern of electrically conductive lines on at least one side thereof; (c) a rigid structural layer; (d) an electromagnetic interference shielding layer; and (e) an optional protective layer.

Abstract: Continuous polymeric extrusion nucleation systems and methods useful for making polymeric microcellular foamed materials, including crystalline and semi-crystalline polymeric microcellular materials, are provided. Pressure drop rate is an important feature in some embodiments, and the invention provides systems for controlling these and other parameters. One aspect involves a multiple-pathway nucleator that is separated from a shaping die by a residence chamber. Another aspect involves a die for making advantageously thick articles, including a multiple-pathway nucleation section. Microcellular material can be continuously extruded onto wire, resulting in a very thin, essentially closed-cell microcellular insulating coating secured to a wire. Other very thin microcellular products can be fabricated as well.

Abstract: A slipper bushing assembly including a series of concentric members for permitting controlled sliding movement between a support element and a movable element. The concentric members of the slipper bushing assembly include a rigid one piece inner metal member joined to the support element, a hollow cylindrical elastomeric member, a rigid, one piece hollow outer metal member, a solid slip surface and structure for preventing the inner metal member from disengaging from the outer metal member. The inner metal member has a pair of opposing ends and an outer cylindrical-like surface. The elastomeric member encircles the outer surface of the inner metal member and has a pair of opposing ends, an outer surface and an inner surface. The outer metal member is joined to the movable element and has a pair of opposing ends and an outer cylindrical surface. The slip surface is contiguous to the inner or outer surface of the elastomeric member and coextensive therewith.

Abstract: A weatherstrip seal comprises a carrier structure without embedded reinforcement that has an attached weather-sealing structure extending therefrom. The carrier structure has two spaced-apart legs connected by a base, the interior walls of the legs forming a channel therebetween. Finger-like members extending from the walls are adapted to frictionally engage and hold a mounting flange inserted into the channel. The legs decrease in thickness as they proceed outwardly from the base and their walls converge inwardly toward each other, minimizing the material required for fabrication of the carrier and enhancing its ability to withstand forces acting to dislodge the mounting flange from the channel, especially at corners thereof.

Abstract: An assembly and method for processing extrudate material containing curves or angles into a predetermined overall configuration, including having a die assembly for an extruder which assembly controls the cross-sectional shape or profile of the extrudate and selectively varies the path of the extrudate as it leaves the die assembly. A support member is provided which has a predetermined overall configuration and profile to receive the extrudate and maintain its configuration. A driving apparatus is also provided for continuously driving either the support member or the die assembly relative to the other while the extrudate is being received in the support member, and until the entire predetermined overall configuration has been completed. The path of the extrudate is variably directed by the die assembly as it leaves the extruder in coordination with the relative speeds involved to conform the extrudate configuration to the predetermined overall configuration of the support member.

Abstract: A method of producing a multicomponent extrudate in which the operating line automatically and accurately extrudes the extrudate materials necessary to obtain the desired contribution of materials and specified dimensions of the multicomponent extrudate profile. The screw speed of each extruder can be adjusted to the desired speed by determining the actual thickness and width dimensions of the multicomponent extrudate. The actual measurements are then fed to a computer which calculates the corresponding values of the ratios of the extruder screw speeds to line speed. using the specified dimensions desired in the extrudate, the corresponding values for the screw and line speeds are also calculated. A comparison of the speeds based on measured dimensions, with the speeds based on specified dimensions, provides a measurement by which the screw speeds may then be adjusted such that the measurements of the extrudate profile are brought closer to the specified dimensions of the multicomponent extrudate profile.

Abstract: A die assembly for configuring extrudate flow is provided. The die assembly includes a die head having a feed member passage, first and second die head passages, and first and second die surfaces respectively associated with the first and second die head passages. The die head passages are located intermediate the corresponding die surfaces and the feed member passage. A feed member is supported in the feed member passage of the die head and has a feed passage and a feed opening for supplying extrudate to the die head. The feed member is supported for relative movement within the die head whereby the feed opening may be moved to communicate with either the first die head passage or the second die head passage. The central axis feed of the feed opening is moveable with respect to the central axis of the first or second die head passage to correspondingly configure extrudate exiting the respective die head passage when the feed opening is in communication with this die head passage.

Abstract: A rotatable accumulator roll which may move substantially horizontally or vertically is disposed between the die of an extruder and a take-away conveyor to minimize the effects of output surging of the extrudate from the die of the extruder in order to maintain substantially the dimension of the extrudate as delivered to a constant speed take-away conveyor. Variable force is applied to the roll to maintain tension on the extrudate.

Abstract: A method of producing an extrudate using a roller die is disclosed in which on-line adjustments are made to size and shape deviations by changing the rotational speed of the extruder screw, the feed rate to the extruder, or the speed of the take-away device and the rotational speed of the roller die. The size and shape dimensions of the extrudate are measured and used to calculate new values for the screw or take-away speed of the feed rate and the roller die speed. A measurement of the extrudate dimensions may also be obtained at the roller die to provide a faster response.

Abstract: A method of producing an extrudate is disclosed in which on-line adjustments are made to size and shape deviations by varying the temperature conditions in the extruder and by varying the relative speeds along the extrusion line. The temperature conditions can be adjusted by varying the temperature of the stock while maintaining a fixed relationship of the die temperature to the stock temperature to produce deviations in the thickness of the extrudate with respect to the width of the extrudate, and by varying the temperature of the die with respect to the temperature in the stock to produce variations in different thicknesses of the extrudate. The relative speeds along the extrusion line can be varied by changing the speed of the screw in a cold-feed extruder, by changing the feed rate for a hot-feed extruder, or by changing the speed of the take-away device which regulates the speed by which the extrudate is taken away from the extruder.

Abstract: An automatic cooling adjustment system for the forehearth of a glass furnace which enables the minimization of the amount of energy used in the forehearth. The system is utilized in a forehearth wherein a continually activated and adjustable cooling wind apparatus operates in conjunction with an electric or fuel fired heating system which controls or maintains the glass within a desired temperature range and at a predetermined temperature gradient range over the length of the forehearth. An automatic means is provided to adjust the amount of cooling wind and to maintain it at whatever level is required in order to minimize the opposing heating energy required. The system includes a timer which enables small automatic cooling wind adjustments during a first, relatively short time period and which enables temperature stabilization in the forehearth during a second, relatively long time period. The cycle of small adjustments is repeated as necessary to keep the heating system within pre-set energy limits.

Abstract: A molybdenum electrode is mounted in a stepped aperture in the sidewall of the forehearth such that the inner end portion of the electrode is immersed in the molten glass where the molybdenum is effectively isolated from oxidizing agents. The outer end portion of the electrode is shielded in a high temperature alloy steel sleeve, which sleeve is spaced from the electrode to provide an annular space therebetween. A ceramic fiberous material is provided between the inner end of the sleeve and the electrode, and a high temperature alloy steel plug is threadably secured to the outer ends of both the sleeve and the electrode to seal the outer end of this annular space, and to serve as an electrical terminal for the electrode. The molten glass solidifies inside the sleeve's inner end to seal the inner end of the sleeve.

Abstract: The forehearth provides a channel for the flow of molten glass from a tank type furnace to a feeder bowl or the like in order to feed gobs of glass to one of several glassware forming machines provided with glass from a single furnace tank. The forehearth channel has sets of electrodes arranged in each of three discrete zones along the forehearth channel, with the center electrode being at a predetermined and controlled potential with respect to electrodes located at the upstream and downstream ends of each zone. The electrode associated with the downstream end of one zone is also used as the upstream electrode associated with the adjacent zone, and the glass is heated by virtue of the fact that these electrodes are immersed in the glass, with an A.C. single phase voltage being impressed thereon.