Abstract: Microfabricated devices and methods of manufacturing the devices are disclosed. The devices are manufactured from a substrate having microscale fluid channels, and polymerizing a polymerizable mixture in the channels to form stimuli-responsive operating components of the device. The operating components can be functional or structural components. The method of manufacture obviates the traditional assembly of microscale components to form a device because the microscale components are formed in situ on or within the device.

Abstract: A golf ball having a cover composed of a polyurethane formed from a p-phenylene diisocyanate (PPDI) based polyurethane prepolymer is disclosed herein. The PPDI-based polyurethane prepolymer is formed from a PPDI and a polyol such as polycaprolactone. The PPDI-based polyurethane prepolymer is cured with a curative such as a 1,4 butane diol and glycol. The PPDI-based polyurethane cover may be either thermoset or thermoplastic. The PPDI-based polyurethane cover has a high flexural modulus at a lower hardness which gives a better feel yet maintains good distance, higher Bashore resilience, higher tensile strength, higher tear resistance, improved elongation, and better playability and control. These benefits and improvements are exhibited even though the cover of the present invention is thinner than those of conventional golf balls. The present invention also provides new golf balls having durable thin covers thereby enabling golf balls with large cores.

Abstract: A method of creating a locating or load bearing surface having a desired flatness or profile. The method comprises: a) providing a base on which the surface is to be created; b) locating a moulding member having a master surface with the desired flatness or profile facing and spaced from the base; c) supplying a curable material to a region between the base and the master surface whereby the curable material contacts both the base and the master surface; d) curing the curable material; and, e) removing the moulding member so as to leave the surface having the desired flatness or profile provided on the exposed surface of the cured material.

Abstract: The present invention provides a method of manufacturing a vehicle cup holder arm, and a vehicle cup holder assembly produced thereby. The method includes injection molding a first material to form a base including an attachment feature adapted for engagement within an aperture adjacent a cup holder opening in a vehicle. A second material is injection molded to form an arm cup around the base and includes an arm. The second material does not chemically bond to the first material so that the arm cup and arm are rotatable with respect to the base for adjustably securing a cup in the cup holder opening. A third material is injection molded onto the arm to form a soft rubber grip for engaging a cup. The cup holder arm may be movable vertically for adjustment with respect to differently-sized cups.

Abstract: A decorative component (1), in particular designed to constitute a piece of internal trim of a vehicle, including at least a sheet of material (2) provided with stiffening means (3) and having, at least locally, on at least one of its faces, referred to as an aspect conferring face (4), an aesthetic and comfortable aspect. According to the method, the stiffening means (3) include a bead (5) of material, whether continuous or discontinuous, provided on a part at least of the periphery of the sheet (2) to fix its shape according to the shape desired for the component. The method also relates to manufacturing such a decorative component and to a use thereof, as well as to a process for manufacturing a piece of internal trim of a vehicle, for example a door panel, using the decorative component.

Abstract: A method for forming a headliner assembly includes forming a main body having a periphery, and a shape corresponding to a desired shape of the headliner assembly; positioning the main body in a mold having a recess; closing the mold; and injecting foam into the recess to simultaneously form an energy absorbing member and join the energy absorbing member to the main body proximate the periphery of the main body.

Abstract: A method for packing a stationary phase into a small diameter fluid passageway or flow channel. Capillary action is employed to distribute a stationary phase uniformly along both the length and diameter of the flow channel. The method disclosed here: 1) eliminates the need for high pressure pumps and fittings and the safety hazards associated therewith; 2) allows the use of readily available commercial microparticles, either coated or uncoated, as the stationary phase; 3) provides for different types of particles, different particle sizes, and different particle size distributions to be packed in sequence, or simultaneously; 4) eliminates the need for plugging the flow channel prior to adding the stationary phase to retain the packing particles; and 5) many capillaries can be filled simultaneously.

Abstract: The present invention relates to an improved casting process of mass producing complete lightweight cementitious house walls. More specifically, the invention relates to the manner in which thin cementitious skins are separately cast on either face of the wall against a sub-assembly of thick panels of insulation material shaped and located in a manner to control the movement of displaced cementitious fluid so that the exposed top and bottom chords of small vertical structural trusses, sandwiched between these the panels of insulation and other perimeter reinforcing members are encased with the least amount of cementitious material. The size and strength of each wall component can be varied to achieve the specific characteristics of the wall. Smooth or textured faces in the casting beds reproduce whatever profiles are of required on the finished walls. Accurate window and door openings are cast in such a manner as to eliminate the need for trim.

Abstract: A geometric-shaped core (12) for a golf ball (10) has a plurality of outwardly extending projections (14) formed on a spherical central portion thereof. A layer (22) of a relatively less resilient material is applied in the interstitial space between the projections (14) on the surface of the core (12), and a cover (24) is applied over the core (12) and interstitial layer (22). The geometric-shaped core (12) is manufactured by first providing flexible, resilient, honeycombed inserts (42) to be used in a conventional compression mold (30). The inserts (42) are placed into the upper and lower mold cavities (30), the core material (40) is added, and the geometric-shaped golf ball core (12) is compression molded.

Abstract: In a method of producing a composite insulator having a core member, end fitting members fixed to both end portions of the core member, and an overcoat member including a sheath portion formed on an outer surface of the core member and shed members, the overcoat member and the end fitting member are connected by curing. Moreover, a clamping operation is performed or a packing member is used for preventing a flow of an overcoat forming material into a seal portion. In this manner, it is possible to improve a seal performance of a connection boundary between the end fitting member and the overcoat member.

Abstract: A method for forming an absorbent article having an absorbent pad assembly with an outer fluid-contacting surface including discrete portions of different absorbency is provided. At least first and second absorbent pad materials are helically wound adjacently about a shaft member whereby at least a portion of each of the first and second absorbent pad materials includes an outer surface exposed portion.

Abstract: A wafer carrier is formed from at least two different melt processable plastic materials in which the two plastic materials are strategically positioned for optimal performance and have a thermophysical bond created during an overmolding process. The invention includes carriers made of such different melt processable plastic materials and includes the process for manufacturing such carriers. In a preferred embodiment a H-bar wafer carrier will have a first structural portion molded of polycarbonate in a first mold cavity and will then have the polycarbonate molded portion placed in a second mold cavity and polyetheretherketone will be injection molded to form wafer contact portions on the H-bar carrier. Process temperatures and mold temperatures are controlled to provide optimal bonding between the dissimilar materials. Thus, an integral wafer carrier of composite materials is formed.

Abstract: A roller body having a shaft formed from a first thermoplastic material and defining at least one roller. The shaft is a single component injection-molded shaft. A casing at least partially encases the roller and is formed from a second thermoplastic material different from the first thermoplastic material. The casing is bonded to the roller by an injection-molding process.

Abstract: A method of producing a partially covered panel comprising a series of manufacturing steps. A covering is formed to have a perimeter portion. The covering is generally formed using a thermoforming operation. The perimeter portion is formed into a flange-shape. A mold movable between open and closed position is moved to an open position. The mold includes a first and second surface. The covering is placed juxtaposed the first surface. A retainer is extended to retain the covering in position prior to and during the molding operation. The retainer engages the perimeter flange portion of the covering. The mold is moved to the closed position. The retainer, covering and first surface define a first cavity section. A first quantity of molten plastic is injected under pressure into this first cavity section. The molten plastic pushes the flange portion against the retainer and the retainer prevents the seepage of plastic between the first surface and the covering.

Abstract: A foil-covered automotive interior plastic part including a decorative preform is provided including a hot stamping foil having a foil top layer disposed on a plastic bottom layer which, in turn, is bonded to a outer surface of a plastic structural substrate at foil-receiving portions of the outer surface. A hot stamping machine is operated for a time sufficient to generate a pressure and temperature sufficient to melt and combine the top surface of the foil-receiving portions and the plastic bottom layer of the hot stamping foil to form the foil-covered plastic part. The at least one foil-receiving portion includes a plurality of raised design portions having top and side surfaces. The foil layer completely covers the top surfaces but only the side surfaces of the raised design portions which extend above a front surface of the preform. Preferably, the raised design portions represent screw heads.

Abstract: Method for encapsulating a chip (10) on a carrier (12) whereby the chip (10) is positioned on the carrier (12), a dam (16a, 16b) is formed on the carrier (12) around the chip (10), encapsulating material (18) is poured into the space within the dam (16a, 16b), and the obtained encapsulated structure is cured. In a first separate step on the carrier only the dam (16a, 16b) is formed from a thermohardening material at a relatively high temperature and is cured at least partly and in a succeeding second step the space within the dam is filled with the same thermohardening material at a relatively low temperature.

Abstract: A process for making a padded armrest on an interior door panel of an automotive vehicle includes the step of conforming an outer cover to a contoured surface of a mold. A blocking device is then placed against a portion of an inside surface of the outer cover and a rigid substrate if formed against the inside of the outer cover and about the blocking device providing a support structure for the outer cover. The blocking device is then removed from the outer cover and mold to form a cavity in the substrate defined by a portion of the outer cover. A resilient foam pad is inserted or formed within the cavity to provide local padded support to the outer cover.

Abstract: A method and system for inserting a golf ball precursor product into a cavity of a mold half for precision centering is disclosed herein. The precision centering allows for the concentricity of core in relation to the cover of a golf ball. The system includes an insertion mechanism that allows for the vertical movement of a plurality of vacuum cups along a longitudinal pathway. The vacuum cups retain the golf ball precursor products and insert each into a corresponding cavity on a mold half. As the vacuum cups are lowered along the longitudinal pathway, the mold half is elevated along the longitudinal pathway. The mold half and vacuum cups meet at an insertion position where the golf ball precursor products are released from the vacuum cups and set within a thermoset material contained in each of the cavities.

Abstract: A method of forming an overcoat member of a polymer insulator having a core member. The overcoat member is made of a sheath portion arranged around the core member and includes a plurality of sheds. The overcoat member is formed by using a metal mold, and during a forming operation, a spacer for maintaining a thickness of the sheath portion is arranged to a portion of the metal mold corresponding to the sheath portion.

Abstract: A method of producing a bead inductor includes the steps of forming an outer portion outside of a conductor coil, and forming a molded body with the conductor coil embedded therein. The outer portion is formed outside of the conductor coil by disposing the conductor coil in a cavity defined by first and second mold portions, with first and second gates formed in the first mold portion, inserting first and second spacer pin portions, which define a spacer pin which passes through the conductor coil and extends to and closes the second gate, and supplying material containing magnetic powder into the mold cavity from the first gate. The molded body is formed by closing the first gate after the formation of the outer portion, and supplying from the second gate material containing magnetic powder into a space formed by removing the spacer pin portions.

Abstract: Brassiere underwires are made in a three step process in which, initially, pairs of injection molded polyamide tips are formed on a continuous flexible strand of carbon fiber or aramid fiber material which can be baked to impart stiffness thereto. In a second step, the strand is cut between the tips to form lengths having the tips at extremities thereof. The lengths are then shaped in a half barrel or plate mold and baked to harden the materials.

Abstract: Method and apparatus for manufacturing a synthetic resin-made hollow member incorporating an intermediate element are provided which enable operations of molding half bodies, abutting and joining the half bodies together, and molding an intermediate element in a series of steps, and which eliminate the necessity of such a manual work as may otherwise be required in incorporating the intermediate element into the half bodies. A pair of rotary injection molding dies are used which can be opened and closed relative to each other and are rotatable relative to each other over an angle of 60° for each turn, each die having a half body molding section including one male molding portion and two female molding portions in the direction of rotation for each rotational run over an angle of 120°, each die also having an intermediate element molding portion provided between specified half body molding portions in the direction of each rotational run over an angle of 120°.

Abstract: Method and apparatus for manufacturing a synthetic resin-made hollow member incorporating an intermediate element are provided which enable operations of molding half bodies, abutting and joining the half bodies together, and molding an intermediate element in a series of steps, and which eliminate the necessity of such a manual work as may otherwise be required in incorporating the intermediate element into the half bodies. A pair of rotary injection molding dies are used which can be opened and closed relative to each other and are rotatable relative to each other over an angle of 60° for each turn, each die having a half body molding section including one male molding portion and two female molding portions in the direction of rotation for each rotational run over an angle of 120°, each die also having an intermediate element molding portion provided between specified half body molding portions in the direction of each rotational run over an angle of 120°.

Abstract: In an air passage switching door, a packing material having a size approximately corresponding to a plate surface of a door base member is used, and the door base member is crossed with the packing material at a portion around a rotation shaft for rotating the door base member, so that both plate portions of the door base member are bonded to opposite surfaces of the packing material at different areas of the packing material. Accordingly, the air passage switching door can be manufactured using the single packing material in low cost, while having a reduced thickness.

Abstract: A helical antenna having an antenna element covered with an insulating layer is formed by monolithically form the insulating layer so that the antenna element is integrated with the insulating layer. To be more precise, first, a cylindrical shell, which received a core pin in its center hole, is inserted into the antenna element along the longitudinal axis of the antenna element. The antenna element is put in a cavity of a molding die. A moulding resin which was heated and molten at a temperature higher than the melting point of the cylindrical shell is injected into the cavity to form an insulating cover over the cylindrical shell and the antenna element. The surface of the cylindrical shell starts softening upon contacting with the molten resin, and sticks around the helically coiled antenna line, whereby the pitch of the antenna element can be maintained substantially constant even if an injection pressure is applied during the molding.

Abstract: A method of compression moulding an article from rubber moulding material incorporating hollow inserts avoids damage to the inserts. Where compression moulding takes place in an enclosed mould at an elevated pressure, the pressure can distort and damage the hollow inserts especially if they are of plastics. In order to avoid such distortion and damage, the method compresses during moulding creating a pressure in a cavity of the insert which substantially balances the pressure exerted on the exterior of the insert by the rubber moulding material in the mould. The pressure in the cavity is preferably produced by introducing some rubber moulding material into the cavity of the insert. This material becomes pressurized during moulding and supports the interior of the insert.

Abstract: A helical antenna having an antenna element covered with an insulating layer is formed by monolithically form the insulating layer so that the antenna element is integrated with the insulating layer. To be more precise, first, a cylindrical shell, which received a core pin in its center hole, is inserted into the antenna element along the longitudinal axis of the antenna element. The antenna element is put in a cavity of a molding die. A molding resin which was heated and molten at a temperature higher than the melting point of the cylindrical shell is injected into the cavity to form an insulating cover over the cylindrical shell and the antenna element. The surface of the cylindrical shell starts softening upon contacting with the molten resin, and sticks around the helically coiled antenna line, whereby the pitch of the antenna element can be maintained substantially constant even if an injection pressure is applied during the molding.

Abstract: A method for manufacturing sealing tool comprising a socket (3) and a head (4) at one end and the other end of a linear element (2) respectively and a protrusion (11) for locking the head (4) in a head-insertion hole (10) of the socket (3), which comprises the steps in the mentioned sequence of fixing a core ball (13) and either the socket (3) or the head (4) to the linear element (2), cutting the linear element (2) at a point close to the core ball (13), pulling the linear element (2) to bring the core ball (13) to be set in a cavity (27) and filing a synthetic resin in the cavity (27) in a manner such that the core ball (13) and the socket (3) engageable with the head (4) are integrally formed.

Abstract: A method for forming a headliner assembly includes forming a main body having a periphery, and a shape corresponding to a desired shape of the headliner assembly; positioning the main body in a mold having a recess; closing the mold; and injecting foam into the recess to simultaneously form an energy absorbing member and join the energy absorbing member to the main body proximate the periphery of the main body.

Abstract: A method of producing dashboards, door or side trim panels for motor vehicles with a predetermined breaking line for an airbag flap is described. To accomplish this, slush material is introduced into a mold which can be heated to a molding temperature and determines the shape of the slush membrane, where the slush material is distributed and deposited on the heated mold surface by rotating the mold and is then sintered and gelled. After cooling the mold, the slush membrane is removed from the mold by unmolding. To create a predetermined breaking line, a mold having a divider on its mold surface at the location of the predetermined breaking line to be created is used. By controlled rotation and/or positioning of the mold while applying the powder and/or gelling the slush material, a reduction in the layer thickness of the slush material to an extent that establishes a predetermined breaking line is achieved.

Abstract: A pressure vessel includes a polyolefin extruded tube, a polyolefin flange overmolded onto the tube, and a cap engaged to the flange. In the overmolding process, a polyolefin material is overmolded unto a polyolefin substrate.

Abstract: A process is disclosed for overmolding crosslinked tubing ends onto a crosslinkable tube. The tube, made of a first polymer, has an inner diameter. The tube is inserted at least partially into a mold and at least partially onto a cylindrical mandrel having a base and a tip. The mandrel has an outer diameter dimensioned to allow the inner diameter of the tube to slide thereon. The mold contains a void for injection of a second polymer. The void co-acts with the mandrel and the tube to define an overmolding shape. After injection molding the second polymer over the tube and the mandrel in the void of the mold, the first and second polymers are crosslinked. Different embodiments of the overmolding shape are taught.

Abstract: Methods for preparing a panel unit having a panel and a frame in which a first molding piece is formed by engaging an extrusion port of an extrusion molding die with a peripheral edge of the panel and extruding an extruded molding material along the peripheral edge of the panel. The extruded molding material preferably simultaneously bonds to the peripheral edge. Waste pieces may be eliminated from the first molding piece after bonding the first molding piece to the peripheral edge and the frame may be completed by adding an additional molding piece to provide a continuously formed frame around the peripheral edge. The first molding piece may be formed by continuously moving the peripheral edge relative to the extrusion port in a predetermined orbital path. The peripheral edge of the panel may be subjected to a primer treatment before engaging the extrusion port.

Abstract: A method of curing large endless track rubber belts uses a multi-platen mold assembly with a pair of fully supporting indexing wheels, non-preformed lug preparation and a post-forming cavity pressure reduction to provide cured tracks with non-deformed reinforcing members while avoiding the extrusion of rubber compound out of the ends of the molds. Also provided is an apparatus for curing large endless track belts having fully supported indexing wheels.

Abstract: A neck flange supports a tracheostomy tube inserted into the neck and has a neck engaging portion of a molded thin flexible flat sheet of a transparent polymer. An interconnection positioned centrally within the neck engaging portion and carried thereby has a ring shaped body with an opening and a pair of opposed pivot pins extending inwardly into the opening for carrying the tube passing therethrough. The pair of opposed pins fit for movement within recesses in the tube to permit limited swivel motion. The interconnection is molded of a transparent polymer material that is less flexible than the neck engaging portion and has a stepped cross section so the pair of opposed pivot pins are raised relative to the ring shaped body. The neck engaging portion is molded about the interconnection so the raised pair of opposed pins remain exposed.

Abstract: Method for decorating the top of a compression-molded cap of synthetic material intended to close a container, in which the decoration is positioned on a flat support in the form of a disc which is placed in the cavity of the cap forming mold before the constituent material of the cap is introduced, and is found to be bonded to the top of the cap after its removal from the mold.

Abstract: A process for producing a pipe fitting of thermally weldable material for attachment to or repair of conduits of thermally weldable material. The first injection mold has channels formed as windings and having channel walls. A heating wire is formed to a wavy heating strand which is laid into the first injection mold between the channel walls. A first welding material is introduced into the channels so that a first broad side of the wavy shape of the heating strand is pressed against a first mold surface of the injection mold and an intermediate product with embedded wavy heating strand is formed. The outside surface is formed by the first mold surface against which the heating strand is pressed and provides the contact surface with the conduit in the end product. The first broad side of the wavy shape of the heating strand remains visible at the outer surface of the intermediate product.

Abstract: Provided are a conductive resin composition having little negative impact on the environment, a resin molding which includes conductive parts of the conductive resin composition and insulating parts, and their methods of production. The production costs for the resin molding are low. The conductive resin composition is formed by kneading a thermoplastic or thermosetting resin with a low melting point alloy, wherein the low melting point alloy is moldable with the resin and consists essentially of tin and is free of lead. An insulating body is formed through primary molding of a thermoplastic or thermosetting resin, and is integrated with conductive parts of the conductive resin composition through secondary molding; or alternatively, conductive parts are formed through primary molding of the conductive resin composition and an insulating body is formed while being integrated with the conductive parts through secondary molding.

Abstract: An apparatus for manufacturing a plug and the manufacturing method. The method includes the following steps. A baseplate located in the bottom of a closed printing chamber is provided. A printed circuit board and a stencil are mounted on the baseplate in sequence. The stencil is aligned to the printed circuit board. An amount of preheated paste is placed on the stencil. A pressure of the closed printing chamber is adjusted to a first pressure. A printing step is performed to form plugs in the printed circuit board. The pressure of the closed printing chamber is adjusted to a second pressure to remove voids trapped in the plugs. The pressure of the closed printing chamber is adjusted to a third pressure. A scraping step is performed to remove the redundant paste.

Abstract: A method for molding a layer around a body. The method includes injection molding uncured layer material around a first portion of the body to surround the first portion while leaving a second portion of the body free from layer material. Additional layer material is injection molded around the second portion of the body to contact the layer material around the first portion. The layer material is then compression molded around the body and cured.

Abstract: The object of the invention is to provide a method for molding a resin-molded article having an excellent surface appearance without any resin-intrusion part on the front surface of a skin thereof. In the invention, the skin is placed on a part of a inner wall of a mold and then injecting a synthetic resin into a cavity of the mold to effect an integral molding of a resin-molded article having the skin on a part thereof, wherein a mold having a first gate on a first inner wall part located on the part other than the back surface of the skin placed on the inner wall of said mold and a second gate on a second inner wall part which faces the back surface of the skin placed on the inner wall is employed; and wherein the synthetic resin is first injected from said first gate until the tip portion of the synthetic resin comes close to the edge of said skin, and then the synthetic resin is injected from the second gate.

Abstract: A closure for a container, and a method for producing the same, wherein the closure includes an end panel and a plastic frame member connected together and which can be place over, or snapped onto, and then the frame member can be permanently attached and hermetically sealed to the flange of a metal, glass, plastic or composite container or can. The interface of the end panel and frame member is such as to hermetically, seal the container and yet the end panel can be readily peeled from at least a portion of the frame member for gaining access to the interior of the container. A pull tab, or ring, is provided to assist in peeling the end panel to an open position. Depending on the manner of attaching or securing the end panel to the frame member, separation or peeling can result from an adhesive failing or from a cohesive failing of the material forming the frame member, or the end panel, or the adhesive.

Abstract: The invention utilizes the adhesive properties which plastic material exhibits while still hot combined with a multi stage molding operation wherein one side of an insert or core located in one side of a mold is coated with molten plastic on a first closing of the mold, the mold is then opened with the plastic still hot to remove the insert or core from the one mold side by virtue of its adherence by the hot plastic to the other mold side, a second charge of plastic is then introduced into the said one mold side and the mold is closed again with the plastic in a molten state to complete the encapsulation of the insert or core.

Abstract: A method and apparatus for encapsulating a ring-shaped member, such as a wound coil of wire, a wound metal ribbon, or a metal composite material. The ring-shaped member is mounted upon a mandrel. The mandrel and the mounted ring-shaped member are positioned in a first mold. A thermoplastic material is injection molded peripherally about a first inner void between the mandrel and the ring-shaped member and a first outer void between the first mold and the ring-shaped member. The mandrel is moved with respect to the ring-shaped member. The mandrel and the re-mounted ring-shaped member are positioned in a second mold. The thermoplastic material is injection molded into a second inner void between the mandrel and the ring-shaped member and within a second outer void between the second mold and the ring-shaped member. The second fill of the thermoplastic material joins with the first fill to fully encapsulate the ring-shaped member.

Abstract: A driving tool, such as a screwdriver, has a handle with an injection-molded, relatively hard and rigid inner body, molded around a tool shank, the inner body having an elongated central portion with two end flanges extending laterally outwardly of the central portion around the entire periphery thereof, with the central portion having a peripheral groove formed therein adjacent to an end flange. An outer gripping body of a relatively soft and resilient material is injection molded around the inner body, surrounding said central portion of said inner body and filling said groove.

Abstract: Printing techniques are used to build three dimensional structures by depositing successive layers of the device onto a substrate. The layers and/or portions thereof are different materials, e.g., conductors and insulators, which provide the desired functional characteristics of the device. The substrate may be used only to provide a support for the printing process, in which case it will usually be removed after the device is fabricated, or may instead be a functioning part of the fabricated device.

Abstract: A thread-wound golf ball comprising a large, heavy center with rubber thread windings and a cover is disclosed. The center has a diameter of about between 1.40″ and 1.53″, a weight of about between 24-34 g and a deformation of about between 0.080-0.160″ when subjected to a 200 lb. load. The cover is a thermosetting or thermoplastic material with a hardness range between 40-70 Shore D. A golf ball according to the invention exhibits the combined superior characteristics of two-piece and three-piece golf balls, i.e., ease of manufacture, feel, playability, durability and distance travel.

Abstract: A method of forming a tip on a catheter having a elongate shaft. The method includes the step of positioning a first tubular member so that it is overlying the distal portion of the elongate shaft. The method further including the step of positioning a second tubular member so that a proximal end of the second tubular member is proximate a distal end of the first tubular member. The method further includes the step of positioning a third tubular member so that it overlays both the first tubular member and the second tubular member. At least the distal portion of the elongate shaft is then heated, wherein the first tubular member, the second tubular member, and the third tubular member are fused to form a catheter tip affixed to the distal portion of the elongate shaft.

Abstract: A multi-stage method of insert molding is described including the steps of: providing a vertically movable first mold member with a cavity formed therein; providing a second mold member having a substantially flat upper molding surface; providing a third mold member having an upper end with a cavity formed therein; positioning an insert directly on the flat upper molding surface of the second mold member; positioning the first mold member with respect to the second mold member so that the cavity of the first mold member receives the insert; injecting a first flowable plastic material into the cavity in the first mold member to partially encapsulate the insert; allowing the first flowable plastic material to cool and solidify, thereby creating a first stage molding; removing the first mold member and the second stage molding from the second mold member; positioning the first mold member with respect to the third mold member so that the first stage molding registers with the cavity of the third mold member; inj

Abstract: A solderless twist on wire connector and a method of making a solderless twist on wire junction encapsulating twist on wire connector by securing a prior art twist on wire connector in a shell to produce a wire junction encapsulating twist on wire connector that can in one operation permit the user to twist the connector to simultaneously compress the junction ends of electrical wires into low resistance electrical contact while encapsulating the junction ends of the electrical wires in a solderless substance. The process includes the method making a twist on wire connector by encapsulating a prior art twist on wire connector in a shell to produce a wire junction encapsulating twist on wire connector having a chamber for an encapsulating material. In one embodiment the twist on wire junction encapsulating twist on wire connector includes a puncturable seal and in another embodiment a second compartment for holding a mixable encapsulating materials.