Abstract: A manifold assembly for a heat exchanger is manufactured and assembled by separately molding a tank portion and a header portion, and assembling the tank and header portions together by positioning them relative to each other and injecting a sealing substance in a cavity that is formed when the portions are so positioned. Ribs are incorporated in the tank and header portions to increase the interface area between the molded portions and the sealing substance, to achieve a mechanically sound, leak proof assembly without using gaskets or fasteners.

Abstract: Thermoplastic elastomeric compositions and processes for preparing the compositions comprising a blend of polypropylene, styrene-ethylene butylene-styrene copolymer, ethylene-propylene-diene monomer elastomer, linear low density polyethylene, peroxide crosslinking agent and a crosslinking coagent. The peroxide crosslinking agent and crosslinking coagent provide a crosslinking system. The compositions improve melt strength and increase resistance to flow and tear. The composition may further comprise mineral oil, antioxidant, colorant, a processing aid and stabilizer and mixtures thereof. The processes for preparing thermoplastic elastomeric compositions are particularly useful in microcellular injection molding to form articles with improved surface characteristics.

Abstract: A method of making an interior trim panel for attachment to structure of a vehicle includes the steps of loading a trim blank into a cavity of a first side of a mold and depositing a molten thermoplastic material onto a core on the first side of the mold. The method also includes the steps of closing the mold, moving the slide in a channel of the core, and injecting a molten thermoplastic material into a second side of the mold to form the interior trim panel.

Abstract: According to the present invention, an in-line compounding and extrusion deposition compression molding apparatus and method for producing a fiber-reinforced molded structural component is provided. The apparatus comprises an extruder device having an internal cavity formed therein and an extruder screw rotatably disposed within the internal cavity for producing a polymer melt. A deposition die head is disposed at a first end of the device, the deposition die head having a die channel disposed therein for receiving the polymer melt from the device. The apparatus includes at least one fiber element for feeding at least one reinforcing fiber element into the die channel for compounding the at least one reinforcing fiber element with the polymer melt to produce a fiber-reinforced polymer compound. The apparatus additionally includes a mold for receiving the fiber-reinforced polymer compound to form the fiber-reinforced molded structural component.

Abstract: Thermoplastic elastomeric compositions and processes for preparing the compositions comprising a blend of polypropylene, styrene-ethylene butylene-styrene copolymer, ethylene-propylene-diene monomer elastomer, linear low density polyethylene, peroxide crosslinking agent and a crosslinking coagent. The peroxide crosslinking agent and crosslinking coagent provide a crosslinking system. The compositions improve melt strength and increase resistance to flow and tear. The composition may further comprise mineral oil, antioxidant, colorant, a processing aid and stabilizer and mixtures thereof. The processes for preparing thermoplastic elastomeric compositions are particularly useful in microcellular injection molding to form articles with improved surface characteristics.

Abstract: Flexible thermoplastic polymer alloy compositions and process for preparing same are disclosed. The composition comprises a blend of about 20 to about 40 weight percent (hereinafter “wt. %”) polypropylene; about 20 to about 50 wt. % uncrosslinked ethylene copolymer; about 2 to about 15 wt. % functionalized polymers, which functionalized polymers typically include maleated polypropylene; and about 1 to about 10 wt. % amines, which amines typically include long chain amines. Processes for mixing the compositions are also included.

Abstract: Flexible thermoplastic polymer alloy compositions and process for preparing same are disclosed. The composition comprises a blend of about 20 to about 40 weight percent (hereinafter “wt. %”) polypropylene; about 20 to about 50 wt. % uncrosslinked ethylene copolymer; about 2 to about 15 wt. % functionalized polymers, which functionalized polymers typically include maleated polypropylene; and about 1 to about 10 wt. % amines, which amines typically include long chain amines. Processes for mixing the compositions are also included.

Abstract: According to the present invention an in-line compounding/extrusion deposition and molding apparatus and method of using the same are provided. The apparatus comprises a single step compounding and extrusion apparatus which includes an extruder screw. The apparatus includes a first zone, a second zone, and a third zone. The first zone is used to melt an inlet material before the screw advances the melted inlet material into the second zone which comprises a preparation and cutting zone. Simultaneously, as the inlet material is melted in the first zone, the screw rotation feeds a reinforcing fiber bundle into the second zone where the reinforcing fiber bundle is prepared for melt impregnation and is sheared to a desired length. While in the second zone, mixing begins between the melted inlet material and the sheared reinforcing fiber bundle.

Abstract: An apparatus having a single screw extruder and a twin screw extruder. The extruders are designed to operate intermittently in a batch-type process. The single screw extruder contains a plurality of barrel segments with an internal cavity, an inlet and a transfer die located at an outlet. The barrel segments provide processing flexibility in that the L/D ratio of the single screw extruder can be varied to accommodate various materials, fillers and material throughputs. The twin screw extruder includes a body having an internal cavity disposed therein. The body includes an inlet at a first end, an outlet at a second end and an inlet located along the length of the twin screw extruder to accept fiber material (fibers) from a side stuffer. A transfer valve is connected to the outlet of the twin screw extruder. The transfer valve controls the flow of melt from the twin screw extruder into an injection plunger.

Abstract: A method of making an interior trim panel for attachment to structure of a vehicle includes the steps of loading a trim blank into a cavity of a first side of a mold and depositing a molten thermoplastic material onto a core on the first side of the mold. The method also includes the steps of closing the mold, moving the slide in a channel of the core, and injecting a molten thermoplastic material into a second side of the mold to form the interior trim panel.

Abstract: Thermoplastic polymer alloy compositions and a process for preparing the compositions are provided comprising a blend of polypropylene, uncrosslinked ethylene copolymer, ionomeric copolymer of ethylene and .alpha.,.beta.-unsaturated C.sub.3 -C.sub.8 carboxylic acid, crosslinking agent, and silicone elastomer. The compositions may further comprise particulate filler, color concentrate and/or coloring pigment. The compositions are particularly useful for forming interior skin sheets for applications where low gloss and high scuff resistance are desired without the need for painting. A one step process for preparing moldable sheets from the thermoplastic polymer alloy compositions by in-line compounding and reactive extrusion is also provided which eliminates separate compounding and pelletizing processing steps as precursors to the sheet extrusion process.

Abstract: A method of making a steering hand wheel insert including the steps of: (a) in a gas assisted injection molding apparatus, forming a mold cavity having a ring-shaped outer channel, an inner channel, and a plurality of spoke channels; (b) forming a stationary mold insert in the outer channel dividing the latter into a pair of symmetric outer channel segments having downstream ends connected by a plurality of choke passages around the stationary mold insert; (c) injecting a short shot of a flowable plastic melt into each of the outer channel segments through a gate diametrically opposite the stationary insert and into the inner channel through a second gate; (d) injecting inert gas under pressure into the flowable plastic melt diametrically opposite the stationary insert; (e) maintaining the gas pressure until all of the flowable plastic melt cures in the mold cavity, (f) relieving the pressure of the inert gas, and (g) opening the mold cavity and removing the molded plastic steering hand wheel insert having a

Abstract: High strength to weight ratio, improved dimensional and surface quality hollow metal moldings are formed by injecting thixotropic, semi-solid metal billets as a "short shot" into a mold cavity; introducing an inert gas into the charge under pressure to force the metal into full and faithful contact with cavity surfaces and to form a hollow portion in the molding; maintaining the pressure of the gas on the charge in the cavity until the metal has solidified and then venting the gas for molded product removal.

Abstract: A vehicle door assembly according to the invention includes a structural framework, including a rear end for mounting a latch, a front end for mounting a hinge and a beam portion extending between the front and rear ends. An outer door panel is provided for mounting on the structural framework to provide the outer surface of the door assembly. A structural inner panel is provided for mounting on the structural framework and is of molded plastic and has a generally planar trim wall facing toward the occupant compartment and edge wall portions which extend transverse to the planar trim wall to thereby envelope the structural framework within the structural inner panel.