Abstract: A method for producing a plastic part having a first component and a second component connected to the first component. The method includes molding a temporary connection between the first component and a preliminary second component, coating at least a surface region of the first component, separating the first and preliminary second component, and then molding the second component to the first component. The plastic part can be an injection molded part and the components of the plastic part can be made using the same or different plastics.

Abstract: A method of making a catheter balloon or other tubular medical device or component, in which a sheet of polymeric material is wrapped on a mandrel and heated to fuse sections of the wrapped sheet together to form a tube. The mandrel has a metallic core and a jacket on an outer surface of the metallic core, and the wrapped sheet of polymeric material is heated without corroding the metallic core of the mandrel. In a presently preferred embodiment, the sheet is formed of a fluoropolymeric material, and the resulting fluoropolymeric tube forms at least a layer of a catheter balloon.

Abstract: The invention relates to a method and device with which it is possible to arrange complicated shapes with considerable differences in height in wood fibre board, and in particular but not exclusively so-called MDF (Medium Density Fibreboard). The deformation of the wood fibre board which can be achieved with the invention is known in the art as extrusion, wherein a considerable plastic deformation takes place accompanied by flow and stretch of the material.

Abstract: A method and an apparatus for making a pipe, and a pipe, wherein the pipe is made from a plastic feedstock pipe by expanding it against a mould. In the first step, that portion of the plastic feedstock pipe (4) which is to have a greater diameter than the rest of the pipe is partly expanded. Only after this is the entire plastic feedstock pipe (4) expanded against the mould (1).

Abstract: An electroconductive resin composition, which comprises a thermosetting resin as a matrix and 40 to 90% by weight, on the basis of the composition, of carbon fibers and graphite as fillers, has a high electroconductivity and is suitable for use as a molding material for fuel cell separators. By using a molding material comprising phenol resin as a matrix and at least one kind of carbon fibers and graphite being coated by an electroconductive metal and molding fuel cell separators from the molding material, followed by post-curing at 130 to 300° C., fuel cell separators with a stable power generation capacity can be obtained.

Abstract: A control panel assembly having a plurality of buttons located in a bezel and supported by a switch mat. A bezel and/or button is formed using a vacuum forming technique and has a transparent inner surface layer and a middle translucent color layer and an opaque outer surface layer. A portion of the opaque outer surface layer is removed to define a desired indicia on an outer surface of the bezel or button. In addition, the bezel or button can be backlit to allow visibility in low light conditions. A method of making a control panel component, such as a bezel or button, is also disclosed.

Abstract: This invention relates to the post-formation processing of extruded or injection molded profiles in an economic manner without the need to purchase a blow molding machine, yet still effect post-formation radial expansion or contraction by the application of sufficient degree of heat or the performing of the operation sufficiently quickly to permit the utilization of the retained latent heat from the extrusion or injection molding process.

Abstract: Complex shaped articles and a method for their manufacture are disclosed. The complex shaped articles comprise a one piece, honeycomb core material that can be conformally shaped for aerodynamic and hydrodynamic movement having formed edges and an outer skin bonded to its top and bottom surfaces to protect and encase the honeycomb core material and provide a drag resistant surface.

Abstract: A method of making a vehicle door assembly by assembling a super-plastic formed inner door panel with a super-plastic formed outer panel. A flanging and roll hemming tool are used to form a hem flange to secure the outer door panel to the inner door panel. A room temperature curable two-part epoxy adhesive is used to lock the inner and outer door panels together. The epoxy adhesive is permitted to cure before the assembly is heated in electro-operations or paint ovens. Hinge and striker attachment areas are provided that are not substantially thinned or stretched during the super-plastic forming process so as to preserve the strength of the inner and outer door panels in such areas.

Abstract: In a process for fashioning a portion of a profiled bead (2), which has been extruded onto an object, in particular a pane (1), fastened in a treatment station (E), in which process an initially shapeless accumulation of material (4) is produced in the portion in question, which accumulation of material is given a final shape corresponding to the uniform cross section, of the profiled bead (2) by means of a moving tool (5), any excess material being expelled in order to be removed, the mass of material (4) is produced by the superposition of two portions of the extruded strip, the second portion being deposited after the die (D) has been moved and repositioned. Advantageously, the tool (5) is, according to the invention, automatically aligned on the profiled bead (2), immediately after the accumulated material (4) has been extruded and after the extrusion die (D) has continued its travel, without moving the object, and is brought into contact with this bead.

Abstract: A process for forming an oriented orthopaedic implant prosthesis bearing, net-shape bearing, or near net-shape bearing includes the step of placing an irradiated UHMWPE preform or puck of a volume sufficient to accommodate the bearing in a compression mold and compression molding the irradiated preform. The molding is accomplished by applying heat and pressure to form the preform into a desired shape. The compression molding induces biaxial orientation in the formed bearing.

Abstract: A method for producing a pressure sensor, in which a semiconductor pressure pick-up is mounted on a mounting section of a lead grid, in particular a leadframe. The semiconductor pressure pick-up is electrically connected to contact sections of the lead grid. The lead grid, together with the semiconductor pressure pick-up, is inserted into an injection molding die. A die part is brought into contact at the side of the semiconductor pressure pick-up facing away from the mounting section or at side of the mounting section facing away from the semiconductor pressure pick-up. The semiconductor pressure pick-up in the injection molding die is subsequently enclosed by a housing made of mold compound. In order to prevent the mounting section from giving way, it is proposed to clamp the mounting section of the lead grid in the injection molding die when producing the housing.

Abstract: A method of making a skin of an interior trim part and an interior trim part made according to the process. A male mold having a convex portion is used to form a skin having a uniform thickness that is sprayed on the surface of the mold. The surface of the mold has a grain pattern that is transferred to a skin. The skin is allowed to flash off or partially cure before being removed from the male mold. The skin is then turned inside out with the exterior surface being inverted to form a convex portion of the skin. The skin is placed into a female mold having a concave portion against which the convex portion of the skin is placed. Foam is injected into the inverted skin while in a female mold and is cured to form an interior trim part.

Abstract: Shape memory alloy and elastically self-expanding endoluminal stents which are at least partially encapsulated in a substantially monolithic expanded polytetrafluorethylene (“ePTFE”) covering. An endoluminal stent, which has a reduced diametric dimension for endoluminal delivery and a larger in vivo final diametric diameter is encapsulated in an ePTFE covering which circumferentially covers both the luminal and abluminal walls along at least a portion of the longitudinal extent of the endoluminal stent. The endoluminal stent is fabricated from a shape memory alloy which exhibits either shape memory or pseudoelastic properties or from an elastic material having an inherent spring tension.

Abstract: The complex shaped articles are formed by trimming, cutting and shaping a honeycomb core material to a desired size and shape, deforming the sized and shaped honeycomb core material at ambient temperature; permanently setting the shape and contour of the sized and shaped honeycomb core material; affixing side edges to the shaped and contoured honeycomb core material; and, bonding a fiber reinforced resin to the top and bottom surfaces of the honeycomb core material.

Abstract: The present invention relates to a process for making polymer tapes utilizing metallocene catalysts. An isotactic propylene polymer is prepared by polymerizing propylene in the presence of an isospecific metallocene catalyst. The resulting polypropylene is heated, extruded and withdrawn as a sheet. The sheet is then slit longitudinally into tape segments and drawn in the longitudinal direction to a draw ratio of at least about 4.5:1 to produce an oriented tape. It has been found that these polypropylene tapes have different characteristics than those polypropylene tapes produced using Ziegler-Natta catalyst drawn at the same draw ratios.

Abstract: The present invention generally relates to interior trim parts such as door panels that are attached to an interior sheet in a motor vehicle. In accordance with the preferred embodiment of the present invention, a method of forming the trim part having an outer surface and an inner surface is disclosed. The method comprises providing a substrate having a first side and a second side and disposing the substrate in a molding tool, the molding tool has an upper mold and a lower mold. Engaging the first side of the substrate with the upper mold and the second side of the substrate with the lower mold. The first side is subject to compression molding such that the first side forms the outer surface of the trim part and injection molding an attachment surface to the second side of the substrate.

Abstract: A molding composition including reactive high-volatility monomeric groups, such as acrylics, at least one primary thermal initiator and at least one secondary thermal initiator is described. Molding process using molding compositions including reactive high-volatility monomeric groups are also described.

Abstract: The present invention relates to a method for making a silicon balloon catheter in which a first tube having its outer diameter slightly smaller than that of a desired catheter is formed by an extruding method, mold lubricant is coated at a portion of a balloon injection opening, a thin film type second tube is formed at the coated outer surface of the first tube by a second extruding, and then the catheter is vulcanized and cut. As a result, when liquid is injected to an expansion tube, the second tube is separated from the first tube, thereby performing a function as a balloon.

Abstract: A process for the hot moulding of articles (L) made of thermoplastic material includes the steps of: heating at least one plate of thermoplastic material (L) to a plasticizing temperature; compressing the heated plate (L) between two moulding surfaces (14, 16), set opposite one another, of a pair of half-moulds (10, 12); and forming, by injection moulding, at least one component (22) anchored to a surface of the plate (L), while the plate is being compressed between the moulding surfaces (14, 16).

Abstract: The present invention provides a process for manufacturing a cross-linked expanded safety support having a cellular structure comprising closed cells. The process involves kneading by thermomechanical working a rubber composition comprising a diene elastomer having a molar ratio of diene units (defined as units resulting from dienes) of less than 15%, water in an amount of from 3 to 6 phr (phr=parts by weight per 100 parts elastomer), a blowing agent, such as azobisformamide, that provides for formation of the cellular structure and a vulcanization system. The rubber composition so prepared is then formed, e.g. by injection or extrusion, into cross-linkable blank, which is then cured in a mold and then demolded. The demolded blank is then expanded by decomposition of the blowing agent and vulcanized to produce the cross-linked expanded elastomeric support.

Abstract: The present invention relates to a method of manufacturing an ocherous panel for use as an interior building material that has excellent insulating properties and that is superior to conventional building materials such as cement, concrete, rock wool and soundproofing boards in strength, fire resistance and soundproofing, and interior aesthetic appeal. The method according to the present invention is characterized in that it uses about 45 wt % of ocher, about 45 wt % of sawdust and about 10 wt % of sodium silicate liquid instead of the composition that was used in the prior art which caused contamination of the air and decomposition of the panel due to absorption of moisture in the air.

Abstract: The present invention is a method for making a composite structure that includes three resin impregnated structural cloth layers including a bottom sheet, a top sheet and a core sheet. The core sheet is a continuously curved shape with flat valleys that are bonded to the bottom sheet and flat peaks that are bonded to the top sheet. In the invention process, a dry core sheet is sandwiched between two wax core molds that form the core sheet. The core molds and the core sheet are sandwiched between dry top and bottom sheets by rigid molds as the flat peaks and valleys of the core sheet make contact with the top and bottom sheets through openings in the core molds. Liquid resin is transferred into the dry sheets and then cured. The lay up is disassembled and the wax core molds are melted and drained from the finished, rigid structure.

Abstract: An apparatus for slush molding a thin shell having an outer layer and an inner layer. The apparatus includes two tubs alternately movable to a cast position for dispensing their respective material contents into a mold cavity. According to another embodiment of the invention, the apparatus includes a diverter valve configured to alternately open a passage from each of two tubs to the mold cavity to selectively dispense charge materials from the respective tubs into the mold cavity. In addition, a method is provided for forming a thin shell having an outer layer and an inner layer. A first polymer material is cast and allowed to melt on a heated mold surface to form an outer layer. A second polymer material is then cast and allowed to melt and form an inner layer on the inner surface of the outer layer. The shell is then removed from the mold.

Abstract: A method of manufacturing a resin spring which can improve close contact between a spring body and inner-pressure generating members to reduce variations in load characteristics due to repeated deformation during use. The method of manufacturing a resin spring includes the steps of forming an elastomer preform having inner closed chambers, compressing the preform by applying an external force to produce a permanently deformed portion to form a spring body having at least one permanently deformed inner chamber, injecting an inner-pressure generating resin into each of the at least one permanently deformed inner chamber of the spring body, and molding the inner-pressure generating resin into an inner-pressure generating member by using the spring body as part of a die.

Abstract: An end face of a plastic optical fiber end is treated so as not to extrude to the core side face when the plastic optical fiber end is softened and fused. The core end face of the plastic optical fiber end is pressed intermittently on a mold that is heated to a certain temperature to soften and fuse the core end face to thereby transfer the transfer face of the mold on the core end face.

Abstract: A method of producing a roll boot from an injection-moldable elastomer, comprising the following steps: injection-molding a basic member having a cylindrical portion and a widened portion; turning the basic member inside out; folding the widened portion outwardly so that it partially comes to lie outwards of the cylindrical portion, forming a roll wall.

Abstract: A mold and a process for use in producing data storage articles such as single substrate double-sided disks. In one configuration, a mold for manufacturing a substrate includes a stamper, at least one holder having an interface with the stamper, and a vacuum line for applying a retention force to maintain the interface between the holder and the stamper. In another configuration, the mold includes a demolding line for applying a demolding force to the substrate to aid in separating the substrate from the stamper. The various embodiments of the present invention provide, among other things, easier and faster stamper changeover, substrates and final data storage articles having improved process indicia such as thickness, flatness, inner and outer diameter, and concentricity, and facilitates production of single-substrate double-sided disks.

Abstract: A sheet shaped key top wherein molded resin key tops are arranged on a sheet, wherein the resin key top is fixed so as to cover the core upper part passing through the sheet, allowing to vary easily the key top design, and permitting a high manufacturing yielding, and a manufacturing method thereof.

Abstract: In a two-layer brush for a commutator, the plane form projected on a commutator surface is nearly similar to the plane form of the segment. A molding die used in brush fabrication has a lower punch which slides obliquely up and down along a sliding groove provided in the lower die, and an upper punch which can slide obliquely up and down in relation to the lower punch. The pressure applying face of the upper punch is formed nearly level, while the pressure receiving face of the lower punch is inclined by a predetermined angle relative to the pressure applying face of the upper punch. It is, therefore, possible to form a first brush material to a predetermined shape, and to apply a uniformly pressure to the second brush powder, to thereby form a second brush material having nearly fixed thickness.

Abstract: In a method of producing injection-molded parts, an injection mold has two mold halves and a melt feeding device for application of melt across the mold surface of a mold half, when the injection mold is open. The melt is pressed into all areas of the mold cavity, when closing the mold halves. In order to simplify the arrangement of the hot runners in the mold half, when different injection-molded parts are produced, it is proposed to apply the melt onto the mold surface by a hot runner plate which is positioned above the mold surface, whereby the hot runner plate has several melt nozzles in the form of needle seal nozzles which are operated and controlled depending on the profile required for the respective mold half.

Abstract: An air bag door construction in which the air bag develops smoothly and securely, the skin can be easily produced. The skin is formed by a mold including an endless and annular wall provided on a molding surface to be inclined relative to the molding surface. A groove portion of the skin formed by the wall is cut at a bottom portion to separate the skin into a general portion and a door portion which are made flush with each other. When the surfaces of the general portion and the door portion are flush the gap between the general portion and the door portion can be narrowed, and gap on the surface is narrowed. When the skin is disposed in the mold for foam forming, the skin can position the general portion and the door portion in the desired position easily, and will not scatter a skin chip in the development of the air bag.

Abstract: A method is provided for manufacturing a painted plastic component having a badge, emblem or other ornamentation, such as air bag covers having a badge, or wherein the component is the badge itself. The method includes providing a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: The present invention provides a tire vulcanizing method for, using a bladder and a tire vulcanizing press, applying preheating and shaping to a green tire externally of the vulcanizing press, subsequently, applying vulcanizing and molding to the entire tire preheated by said vulcanizing press, whereby the time for restricting the tire by the tire vulcanizing press can be shortened, and the cycle time of the tire vulcanizing and molding can be shortened to improve the productivity.

Abstract: The present invention provides a method for producing a bone joining device having a head portion, the method comprising the step of press-molding a (primary) molded article to form a head portion, and a bone joining device having a head portion, wherein the molecular orientation in the (primary) molded article is substantially maintained.

Abstract: A process for producing mono-axially oriented polyethylene terephthalate film having increased mechanical strength in the machine direction which comprises the steps of drying substantially homopolymer or copolymer polyethvlene terephthalate resin having an intrinsic viscosity in the range of about 0.65 to about 0.85 dg/cc and then blending the dried resin with from about 0.5 to about 4.0% by weight of anti-block additive; extruding the resin blend to re-melt the resin and make it homogeneous: casting a film web with the resin blend; orienting the film immediately after casting it to produce a film of uniform thickness, by drawing the film at a ratio of from about 3.5 to about 4.

Abstract: A molded article is produced by a method of compression molding employing a specially shaped billet of thermoplastic material which is positioned at a predetermined location in a predetermined orientation with respect to the mold cavity surfaces of a mold part. In a preferred embodiment, the billet has a generally egg shape and is located adjacent a mold surface defining a small mold cavity region between two larger cavity regions.

Abstract: A method and device of treating an irregularly shaped article to prepare the article for painting is provided. The device includes a burner which can produce an adjustable flame tongue which can fit into crevices, openings and other irregular topographical features of an item to be painted or otherwise coated. The burner device further provides means to apply a grafting chemical on a freshly oxidized surface. Further, the invention provides means to colorize treated objects so that they may be recognized as having been treated. In another embodiment, the grafting chemicals may be enhanced with electrolytic solutions such that electrostatic methods of painting may be subsequently employed on the item. In an alternate embodiment, the burner is adapted to spray a powder inside of a generally enclosed flame, and is used in conjunction with chop guns to manufacture glass or carbon fiber preforms.

Abstract: The invention relates to a method for preparation of test bodies for analysis of porous, preferably thermally sprayed, surface layers, which are incorporated by casting in plastic. The method according to the invention is carried out by placing one or more test pieces of the surface layer in a mould introduced into a vacuum chamber, the pressure of which is lowered, pouring a ready-mixed, liquid casting resin into the mould containing the test pieces, again letting the air in into the chamber, lifting the test pieces out of the casting resin and allowing excess of casting resin to drip from the test pieces, and after that they are placed in a mould cavity of a hot moulding press, filling said mould cavity together with the test pieces with a pulverized resin, and applying pressure and heat to the mould cavity for a predetermined period of time, whereupon the test body is ready to be taken out and lapped.

Abstract: The present invention relates to a method of manufacturing an ocherous panel for use as an interior building material that has excellent insulating properties and that is superior to conventional building materials such as cement, concrete, rock wool and soundproofing boards in strength, fire resistance and soundproofing, and interior aesthetic appeal. The method according to the present invention is characterized in that it uses about 45 wt % of ocher, about 45 wt % of sawdust and about 10 wt % of sodium silicate liquid instead of the composition that was used in the prior art which caused contamination of the air and decomposition of the panel due to absorption of moisture in the air.

Abstract: A method and apparatus for forming a skid-resistant surface on a thermoformed object such as a bed liner. The method includes forming a blank of extruded plastic material, abrading the surface with a wire brush, reheating the blank and thermoforming the blank to open the abraded surface of the blank. The apparatus includes an extruder delivery mechanism delivering a blank of sheet material to a wire brush which is turned by an electric motor at a speed slightly greater and in the same direction as the travel of the blank under the roller.

Abstract: A method and an apparatus for making a pipe, and a pipe, wherein the pipe is made from a plastic feedstock pipe by expanding it against a mould. In the first step, that portion of the plastic feedstock pipe (4) which is to have a greater diameter than the rest of the pipe is partly expanded. Only after this is the entire plastic feedstock pipe (4) expanded against the mould (1).

Abstract: The present invention is a method for forming a corrugated container having a double wall construction. A blank is formed of a pair of corrugated layers sandwiched between and adhered to adjacent flat layers and having a sufficient moisture content to enable the blank to be formed. The blank can include printed indicia, thermoresistant coatings, release coatings, and other coatings applied to the blank to enhance the utility of the container formed from the blank. The blank is then inserted into a thermoforming machine in which a pair of heated dies compress the blank into the desired container shape.

Abstract: Process for manufacturing cold formed shaped forms of packaging having at least one recess from a metal-plastic laminate 20. Examples of such shaped forms of packaging are the base parts of push-through packs or blister packs. The process is such that the laminate 20 is held between a retaining tool 5 and a die 1. The die 1 exhibits at least one opening 8 and a stamp 6 is driven into the die opening 8 causing the laminate to be shape-formed into a packaging, correspondingly exhibiting one or more recesses.

Abstract: A material holding implement including a material holding member adapted for holding a material. The material holding member is made of a thermoplastic resin. The thermoplastic resin is deformable to a material holding configuration at a temperature greater than a constant temperature, and fixable to form a material holding region adapted to apply holding forces on a circumference of the material in a using temperature range lower than the constant temperature. Furthermore, a method of changing a form of the material holding member is provided. The method includes softening the resin by increasing a temperature above the constant temperature, molding the resin into a flat plate by pinching together upper and lower dies having flat surfaces opposing each other, pinching the resin using the upper and lower dies to form a material holding configuration, and fixing the resin by decreasing the temperature below a softening point of the resin.

Abstract: The invention is concerned with an integrated process for the manufacture of polymer and/or composite products, comprising the integration of processing operations to achieve a plurality of material conversion steps, such as impregnation, consolidation and bonding, within one single controlled fabrication cycle. The process includes an in-situ final preparation of at least one composite preform at the location of the moulding operation and an integrated moulding operation comprising a step of providing an additional matrix-functioning material into the mould to at least partially enclose the composite preform, the operation of providing the additional matrix-functioning material providing the pressure for an in-situ final consolidation of the composite product.

Abstract: A composite material blank for an orthotic insert. The device is formed of layers of fiberglass and graphite fiber material. A first graphite fiber layer provides the overall structure with increased strength, while secondary graphite fiber reinforcement strips are arranged below the first and fifth rays of the foot to provide additional rigidity and control in these areas. The edges of the graphite fiber layers are recessed inwardly from the edges of the fiberglass layers so as to provide a graphite-free border which prevents cracks from propagating into the graphite fiber layers. The layers are bonded together by heat curing over molds.

Abstract: A multi-point thin portion compression molding method and apparatus in which a plurality of ultra thin portions can be formed by compression molding. Mold apparatuses are opened/close to each other to form a cavity space having a molded material therebetween, at least one movable telescopic member passes through one metal mold and protrudes toward the other metal mold, the central and outer periphery of the telescopic member are provided with vent portions, and recess portions are formed on the metal mold contacting the vent portions to allow molten resin to escape, and the recess portions adjust a pressure applied to the cavity space by the compressing operation of the telescopic member.

Abstract: A process for formation of a plastic composite includes providing a two part mold system wherein one of the parts is moveable and includes cavities and the other of the parts is stationary and includes cores each having less mass and sequentially moving the moveable mold part with respect to the stationary mold part to form an injection volume between each of said mold cavities of variable capacity.

Abstract: A method for the shaping of strip-like films (2) involves the following steps: a) A film strip (2) is continuously forwarded from a film supply to shaping units. b) The film strip (2) is pleated in a first shaping unit (11). In this, edges (21, 22) are produced which form an angle of inclination to the edges (36) of the film strip having a constant value. c) After a forwarding of the pleated strip (2′) to at least one further shaping unit (12) the former is reshaped in one or more steps. In this the edges (21, 22) are eliminated through plastic deformation by means of a roller pair (120) in edge zones (30b) outside of a middle zone (30a) of the strip and are at the same time replaced by curved edges (31, 32). The angles of inclination of the curved edges continuously increase from the middle zone to the strip edges.