Abstract: The present invention provides composites prepared from melt blending compositions that generally include cellulosic pulp fibers having an alpha-cellulose purity of greater than 80% by weight, at least one water soluble binder, at least one lubricant, at least one compatibilizer, and at least one matrix polymer. The present invention further provides advantageous temperature profiles and feeding arrangements to be used in conjunction with the melt blending of such composites. The composites of the present invention exhibit reduced discoloration and improved fiber dispersion.

Abstract: A method of moulding a high density composite article which, when completed, has opposed outer skins of fibre-reinforced plastics material and polymer mortar core between the skins. The method is performed by (a) providing an openable mould defining a mould cavity and an injection port through which polymer mortar may be introduced into the cavity; (b) opening the mould and placing within the cavity respective layers of fibre reinforcement to form the opposed outer skins; (c) closing the mould and injecting polymer mortar consisting of a resinous material loaded with high density particulate aggregate through the injection port into the cavity, between the layers of fibre reinforcement placed therein; and (d) applying sufficient pressure to the injected polymer mortar to ensure resin is separated from the polymer mortar and penetrates the said layers.

Abstract: The present invention relates to a method of manufacturing a thermally conductive article having an integrated thermally conductive surface. The method involves molding a first thermally conductive composition to form a body of the article and then molding a second thermally conductive composition to form an integrated surface on the body of the article. The integrated thermally conductive surface can interface with a heat-generating device (e.g., an electronic part) to dissipate heat from the device. The invention also encompasses thermally conductive articles produced by this method.

Abstract: In the production of a vulcanized rubber-resin composite material by providing a vulcanized rubber molding in a mold, followed by injecting a resin into the mold, a vulcanizable adhesive layer containing brominated poly(2,3-dichlorobutadiene-1,3) as the main component is formed on the surface to be bonded of the vulcanized rubber molding, and then injecting the resin while keeping the vulcanizable adhesive layer to stay as formed on the surface to be bonded, thereby effecting the bonding, where a strong adhesion is established between the vulcanized rubber molding and the resin layer without any heat treatment of the vulcanized rubber molding before provision of the vulcanized rubber molding in the mold or without any heat treatment of the composite material after the resin injection.

Abstract: The present invention relates to polymer composites comprising at least one, optionally hydrogenated, nitrile rubber polymer having a Mooney viscosity (ML 1+4 @ 100° C.) below 30 at least one filler and optionally at least one cross-linking agent, a process for preparing said polymer composite wherein at least one, optionally hydrogenated, nitrile rubber polymer having a Mooney viscosity (ML 1+4 @ 100° C.) below 30, at least one filler and optionally at least one cross-linking agent are mixed and a process for the manufacture of a shaped article comprising the step of injection molding a polymer composite comprising at least one, optionally hydrogenated, nitrile rubber polymer having a Mooney viscosity (ML 1+4 @ 100° C.) below 30, at least one filler and at least one cross-linking agent.

Abstract: A method of making a composite article of a graphite-filled polymer mixture that is robust during high shear mixing and compounding, and that exhibits relatively low electrical resistivity after molding. The mixture is formed by shear mixing a liquid polymeric material, graphitized carbon fibers having diameters of less than one micrometer, and glass fibers longer than the carbon fibers. The carbon and glass fibers constitute up to about 25 volume percent and up to about 50 weight percent, respectively, of the mixture, though the addition of as little as about 1 weight percent of the glass fibers has been shown to dramatically reduce resistivity. The mixture is then introduced into a mold so that the glass fibers are substantially oriented parallel to the direction of flow.

Abstract: A method and apparatus comprising expanded, or flexible, graphite mixed into a polymer material is disclosed. A method for using expanded graphite that has been pre-compressed prior to milling to enable a polymer material to accept an electrostatic modification to the surface or to dissipate electrostatic discharges. Other embodiments relate to methods of making polymer materials, methods of making molded polymer articles or objects, and methods of electrostatically modifying molded conductive polymer materials.

Abstract: The invention relates to a method for obtaining a clutch lining consisting in: injecting a friction material containing a polyester resin into a mould; the material also contains a polymerisation catalyst, glass fibres, chalk, mica, talc, kaolin, thermoplastic fillers and a mould release agent. The invention also relates to a clutch lining obtained using said method and a clutch disc fitted with one such lining.

Abstract: An improved procedure and apparatus for introducing liquids within a thermoplastic or thermoset production system are provided. Such an inventive apparatus comprises a storage tank for the desired liquid, a device which connects to a flow channel (such as a manifold or pipe) through which the target thermoplastic or thermoset composition is flowing, and a transfer line connecting the storage tank with the connecting device. The connecting device itself easily attaches and detaches to the flow channel through a spring-loaded or sliding-lock mechanism. Such a novel apparatus permits an ease in changeover from one liquid to another without the need for time-consuming cleaning and without complicated shut-off, removal, and replacement steps.

Abstract: The present invention provides a PFA resin helical blade for use in a compressor, which is superior in dimensional precision and surface smoothness with a superior anti-fatigue property, and a manufacturing method thereof. In a manufacturing method of a compressor-use helical blade of the present invention, a PFA composite resin, which is formed by mixing an inorganic filler with a tetrafluoroethylene/perfluoroalkylvinyl ether copolymer (PFA resin) having a —CH2OH terminal group, which has not been subjected to a stabilizing process, and has fluidity of not ness than 15 g/10 min, is used, and after the resin has been molded into a helical blade through an injection-molding process, the resulting matter is subjected to a heating process at a temperature from 280 to 300° C. for a period from not less than 10 hours to not more than 300 hours.

Abstract: An integrally molded brush. A preferred embodiment of the integrally molded brush includes a) a generally planar hub having an outer periphery, where the hub has a thickness of at least 0.05 inches; and b) a plurality of bristles extending from the outer periphery of the hub, where each of the bristles includes a bristle tip opposite the hub, where the bristle tip has a thickness up to 0.03 inches, and where the molded brush comprises a thermoplastic polymeric material. The present invention also provides a method of molding an integrally molded brush. A preferred embodiment of the method includes the steps of: a) heating a thermoplastic polymer to allow the thermoplastic polymer to be injected into a mold; b) injecting the thermoplastic polymer into a mold, wherein the mold includes a hub section and a plurality of bristle sections in fluid communication with the hub section, where the bristle tip section has a thickness up to 0.

Abstract: A particulate polymeric blend for use in the formation of molded products formed in the absence of a compounding and/or extruding step prior to molding. A quantity of reactor flake is blended with at least one additive at a temperature below the melting temperature of the reactor flake to form a particulate polymeric blend. A wide variety of polymeric reactor flake can be used to produce molded products. Molded products produced using these particulate polymeric blends exhibit superior physical properties. Molding processes utilizing such particulate polymeric blends can avoid the use of expensive compounding and pelletizing steps which degrade the quality of the molded polymer.

Abstract: A particulate polymeric blend for use in the formation of molded products formed in the absence of a compounding and/or extruding step prior to molding. A quantity of reactor flake is blended with an effective amount of foaming agent and optional additives to form a particulate foamable polymeric blend at a temperature below the melting temperature of the reactor flake. A wide variety of polymeric reactor flake can be used to produce foamed products. Additionally, a plurality of particulate blends can be blended to provide multiple layer molded products such as foamed-skin products. Molded products produced using these particulate polymeric blends exhibit superior physical properties. Molding processes utilizing such particulate polymeric blends can avoid the use of expensive compounding and pelletizing steps which degrade the quality of the molded polymer.

Abstract: A method of making a thermally-conductive casing for an optical head in a disc player is provided. The method involves molding a polymer composition comprising: i) about 20% to about 80% by weight of a polymer matrix such as polyphenylene sulfide, and ii) about 20% to about 80% by weight of a thermally-conductive material such as carbon graphite into a casing for the optical head. A reinforcing material, such as glass, and other additives, such as flame retardants, can be incorporated into the polymer composition.

Abstract: Improvements in increasing the amount of available silver in thermoplastic articles comprising certain silver-containing antimicrobial agents are provided. Such an invention requires the incorporation of a sufficient amount of a carboxylic acid salt within the thermoplastic article simultaneously with the necessary silver-containing antimicrobial agent. Certain carboxylic acid salts are standard acid scavengers for thermoplastic applications; however, the amounts required within this inventive thermoplastic article is well in excess of that commonly added within such articles. Surprisingly, such an excess amount of such standard salts, as well as other non-standard salts, present within the target thermoplastic causes the release of greater amounts of silver to the target article's surface, thereby permitting a greater degree of antimicrobial activity, among other potential benefits for such an increase in surface-available silver.

Abstract: A process for making a fiber reinforced molded article is disclosed. The process entails (i) melting a thermoplastic resin (ii) introducing and homogeneously distributing at least one fiber strands to the molten resin to form a mixture of fibers and molten resin and (iii) molding the article by injection or by compression molding, and (iv) solidifying the article. The process is characterized in that where the fiber strands have a fiber length of 2 to 25 mm and in that the molded article contains fibers the mean length of which is at least 400 &mgr;m. Lastly the process is characterized in that no cooling or solidifying take place between steps (ii) and (iii).

Abstract: Molding material consisting of resin coated reinforcing fibers in a molten mass of resin and fibers is prepared at a molding site for controlled supply to a molding machine. A conveying device, such as a pair of pinch rollers, serves to pull fibers from supply spools through guide orifices of a coating die having a chamber within which the fiber is coated with molten resin. Further impregnation of the fibers with resin takes place in the conveying device, which also develops pressure on its output side serving to push the mass of hot resin and fiber into a receiving device for movement to a molding machine. The receiving device may be the feed screw for an injection molding machine or simply a plate movable to and from a compression molding machine. The fibers may be cut into predetermined lengths by a cutting device positioned downstream of the aforesaid conveying device.

Abstract: A thermally-conductive plastic substrate for supporting electronic circuits is provided. The substrate has a relatively low dielectric constant and good mechanical strength. The substrate is made from a polymer composition comprising a base polymer matrix and a thermally-conductive, electrically-insulating material. The composition can comprise polyphenylene sulfide and boron nitride. The composition can further comprise a reinforcing material such as glass. The invention also encompasses methods for making such substrates.

Abstract: A method for producing an elongated composite that comprises the use of a cycleable molding apparatus that has (i) at least one extruder, (ii) a mold assembly carousel having an axis, inner circumference, outer circumference, and being rotateable about its axis in a substantial vertical plane and being capable of indexing a mold assembly to an injection station, cooling station, and removal station, and (iii) at least one mold assembly engaged with the outer circumference of the mold assembly carousel. Moldable resin is injected a mold assembly located about the axis of the mold assembly carousel. The mold assembly is rotated to a cooling station or cooling area and later rotated to a composite removal station, where the composite is ejected from the mold assembly.

Abstract: An injection molded product is provided on its surface with a fine grain-like pattern resembling a grain pattern of a natural wooden material. The fine grain-like pattern of the injection molded product 1 (a product part 2) is formed from a molten resin 15 comprising a first material 24 and a second material 25 having a different color, mixed in a substantially separate manner, by feeding the molten resin into a cavity 18 for molding the injection molded product in a form of plural divided streams 26 each having a generally constant width so as to allow the second material to solidify as a trace of each divided streams 26.

Abstract: The invention comprises a plasticating machine for the working and forcing of plastic material into a mold, said machine including an elongated housing having a first or proximal end and a second or distal end, an elongated screw shaft with a screw flight therearound, the screw shaft being rotatably supported in the elongated housing, for the working of plastic between the screw shaft and the elongated housing with at least one delivery conduit generally longitudinally arranged through the screw shaft, from a proximal end to a distal tip end thereof. The conduit may be arranged to be movable with respect to the screw shaft to permit delivery of a medium through the screw shaft to any plastic being driven from the machine. The medium may be any single or combination of components selected from the group comprising vapor, liquid, gas, powder or solid, to control the machine or treat any plastic being driven therefrom.

Abstract: According to a known method for producing a component by means of a powdery starting material, powder is mixed with auxiliaries comprising binding agents, whereby a free-flowing mass is produced. A green body is produced from the mass by means of powder injection moulding. A portion of the auxiliaries is extracted by heating the green body in a container and exposing said body to a stream of solvents. The green body is sintered, whereby the component is produced. The aim of the invention is to enable fast and gentle extraction for releasing green bodies which are produced by means of powder injection moulding. According to the invention, the extraction comprises a heating-up phase during which the temperature of the green body is permanently or gradually increased and the green body is overflown by solvent in the form of a compressed, supercritical treatment gas.

Abstract: In manufacturing glass fiber-reinforced resin moldings a peroxide is mixed into a molding material prepared by mixing glass fibers with a thermoplastic resin, and such a molding material is molded. The peroxide is fed together with the molding material in an injection molding machine, the molding material is heated and kneaded in the molding machine, and the glass fiber mixed molten resin is injected into a mold to obtain a molded body.

Abstract: An molding apparatus useful for molding polymer compositions includes a substrate; a first insulating layer having an electrical resistivity of at least about 1010 ohm-centimeters and thermal conductivity of about 0.2 to about 5 watts/(meter-kelvin); a heating element; a second insulating layer having an electrical resistivity of at least about 1010 ohm-centimeters and a thermal conductivity of at least about 5 watts/(meter-kelvin); and a first molding layer having a specific heat capacity of about 100 to about 2,500 joules/(kilogram-kelvin), and optionally, a second molding layer. The apparatus provides rapid heating and cooling of the mold surface. The apparatus may be employed for rapidly molding articles having desirable surface characteristics.

Abstract: A method of reducing the restrictions of mixing fiber reinforced plastic includes the step of first coating the fiber. The coating is of a sort which will prevent the fiber from beginning to absorb the plastic such that the combined plastic and fiber may be stored for a period of time. Once the combined fiber and plastic are moved towards a mold, a mix station preferably cracks the coating. This allows the fiber to absorb the plastic matrix. The combined fiber and plastic is then delivered into a mold. By allowing the fiber to be pre-mixed with the plastic, the requirement of a “mix room” for mixing fiber into a plastic matrix adjacent to a molding facility is eliminated.

Abstract: In a method of making impact-resistant modified thermoplastic materials, thermoplastic material is introduced in a continuously operating twin-screw extruder having two screws rotating in a same direction and plasticized. Admixed to the thermoplastic material in the extruder at a location well downstream of the feed area of the thermoplastic material is an additive, e.g. impact-resistant modification agent, reinforcing agent, or alloying agent, to produce an extrudate which is conveyed for injection into an injection mold alternately via two injection cylinders or via a storage cylinder and one injection cylinder.

Abstract: A resin molding product of the present invention is a sandwiched molding product provided with a core layer and a skin layer having at least an electrophotographic toner. Further, it is preferable that the core layer contains an additive resin, which is compatible with a binder resin that is used for the electrophotographic toner and can give an elasticity to the core layer when the additive resin and the binder resin are dissolved with each other. According to the arrangement, it is possible to utilize as a raw material a nonstandard toner, which is produced during a manufacturing process of the electrophotographic toner, but cannot be used as a commercial product, and a discard toner, which has been used in an image forming apparatus of an electrophotographic method, thereby realizing a resin molding product of a high quality at a low cost, while the resin molding product can improve its impact resistance by use of the additive resin.

Abstract: The invention relates to methods of forming shaped articles from suspensions which include ceramic or metallic powder, or from solutions or suspensions which include one or more pharmaceutical substances or other components. The method comprises the steps of: (a) combining solvent, polymer, cross-linking agent precursor and optional further components and placing into a mould of desired shape; (b) increasing temperature of mould contents to activate cross-linking agent; (c) allowing mould contents to solidify to sufficient extent to remove mould; (d) removing shaped article from the mould.

Abstract: In a method of making an electrically conductive electrode member, a compound material, containing a binder made of polymer plastic and 80 weight % of a powdery electrically conductive material as filler, is introduced into a plasticizing screw of an injection molding machine for transforming the compound material to a plasticized material and discharging the plasticized material via a nozzle having a length of less than 15 mm for subsequent injection molding. The injection molding machine is constructed throughout a material flow passage from a point of introduction of the compound material to the injection mold to have only tapered portions which narrow a flow cross section by not more than 10:1.

Abstract: This invention describes the use of organoclays as additives to plasticizers to provide a plasticizer composition, to allow the mixing of the plasticizers with thermoplastic resins in the same process used to convert the resin formulation to finished product. The use of this invention eliminates the need for a preliminary compounding step to incorporate plasticizers into thermoplastics prior to extrusion or molding.

Abstract: The present invention provides for a power transfer belt that is manufactured of a highly thermally conductive polymer composition, in contrast to the typical rubber material used to fabricate the belts of the prior art. The new and unique belt of the present invention is manufactured of a thermally conductive polymer material that is easily injection moldable into any desired shape and configuration. Further, the polymer composition is very thermally conductive, which assists in dissipating heat that is generated by the friction created during normal operation of the device. The new belt material and its construction allow heat to be conducted directly through the surface of the belt thus preventing heat buildup within the belt itself, thereby preserving and extending its life. Further, the present invention provides a novel method whereby a thermally conductive belt is manufactured through net shape molding.

Abstract: A lead-free super-highly conductive plastic is formed of a conductive resin composition which includes a thermoplastic resin, a lead-free solder that melts during plasticization, and metal powder or a mixture of metal powder and metal short fibers that promotes the fine dispersion of particles of the lead-free solder within the thermoplastic resin. In the lead-free super-highly conductive plastic, since particles of the lead-free solder are connected with each other via solder melted within the plastic, the particles of the lead-free solder are mutually joined, so that high conductivity is attained.

Abstract: Heat dissipation devices and molding processes for fabricating such devices, which have at least two regions comprising different conductive materials such that efficient thermal contact is made between the different conductive materials. The molding processes include injection molding at least two differing conductive materials.

Abstract: An injection-molding process including kneading functional particles with a binder resin in a kneader, temporarily storing the kneaded material supplied from the kneader in a reservoir device and feeding the kneaded material stored in the reservoir device to an injection device, the reservoir device including a pair of reservoirs, the kneaded material stored in one reservoir device is fed to the injection device where the kneaded material is then injection-molded, and simultaneously the kneaded material is fed from the kneader to another reservoir device and stored in it. Then, the kneaded material stored in the other reservoir device is fed to the injection device where the kneaded material is then injection-molded, and simultaneously the kneaded material is fed from the kneader to the one reservoir device and stored in it, so that the injection molding process is conducted by alternately repeating the above steps by switching operations.

Abstract: A method of moulding and a moulding installation is disclosed. The installation comprises a compounder (16), a flow path (26) from the compounder to a vessel (34) in which the mouldable material emerging from the compounder is accumulated, and further flow paths (28) from the vessel (34) to a number of moulders (30) each of which is associated with a mould (32). The moulders take charges of mouldable material on a cyclical basis.

Abstract: Reinforced plastic pellets comprise thermoplastic material and reinforcement particles that are less than 15% of a total volume of the pellets, and at least 40% have a thickness of less than 50 nanometers. A manifold (56) has at least two spaced valve gates (64) that are independently opened and closed as directed by a controller (68) to selectively communicate the manifold to a cavity. A primary injection pressure is applied to the plasticized pellet material in the manifold (56) to fill the cavity through sequential opening and closing of the gates (64). A lower secondary injection pressure is applied to the material in the manifold to continue filling the cavity. The gates are closed to seal the manifold from the cavity when the cavity is filled. The material is held within the manifold in compression by the valves while the cavity is open to prevent expansion of the material.

Abstract: The present invention provides the use of a mineral oil in a fluoroelastomer composition comprising a fluoroelastomer to improve the flow of said composition during processing to form an article therefrom and/or to improve the release from a mold of a vulcanized article produced from said fluoroelastomer composition. Further provide are a fluoroelastomer composition that includes a mineral oil, a method of making an article therewith and a method of preparing the fluoroelastomer composition.

Abstract: A process for the manufacture of thin-walled articles comprising the steps of: 1) selecting a polymer blend having an ESCR of greater than 10 hours; i) a plurality (preferably 6 or more) of strips of the polymer blend incorporating any post molding treatment intended for the final article having the cross-sectional dimensions of 0.65 mm in thickness and 10 mm in width are injection molded under high shear, long flow length conditions, similar to those intended for use in the manufacture of the flexible thin-walled article; ii) the strips are bent back upon themselves and stapled 3 mm from the bend; iii) the bent strips are immersed in a solution of a stress crack agent and held at a temperature of 50° C.

Abstract: A method for manufacturing products with a blown foamy structure, starting from a mass comprising at least natural polymers such as starch and fibers, in particular natural fibers, wherein the mass (M, S) is passed under pressure into or through a mould (23, 63) and the mass (M, S) is heated in the mould (23, 63) in a manner such as to give rise to gelatinization and cross-linking of the natural polymers, with the fibers extending through the product, while the mass prior to the introduction into the mould has temperature which is below the gelatinization temperature and in the mould is brought at least to the baking temperature.

Abstract: Granulated papermaking sludge is combined with plastic to form composite materials that may be shaped into structural and non-structural articles.

Abstract: An FRP molded article molded by hot runner injection molding with a mixture of thermoplastic resin and reinforcing fibers of 0.1-7 mm in average length dispersed in the thermoplastic resin; and a hot runner injection molding method therefore. The molded article is preferable for use as a housing for electronic terminal equipment, cellular phones, etc.

Abstract: By molding a biodegradable plastic material which is treated with a compound reactive to the active hydrogen in the biodegradable plastic material, a biodegradable plastic material and molding having long-term reliability are obtained.

Abstract: A process for preparing an injection-molded cutlery The process includes providing a mixture of a filler and a polymer The mixture comprises from about 30 to about 70 wt. % filler and from about 30 to about 70 wt.

Abstract: There is disclosed a process for melting a luminescent oxygen sensitive compound into extruded polymer films. Specifically, there is disclosed a process for thermal melting of oxygen-sensitive indicators into common packaging polymers used for commercial packaging of products, such as foods. The oxygen-sensitive indicators can be used for real-time monitoring of oxygen in commercial packaging operations.

Abstract: Methods of manufacturing a sealing or an anti-extrusion component for use in a downhole tools is described. The method includes formation of the component from a composition that contains a polyetherketoneketone or a derivative of a polyetherketoneketone. The resultant component is adapted for use in a downhole tool. The invention is also a sealing or an anti-extrusion component for use in a downhole tool. The component contains a composition, which itself is composed of a polyetherketoneketone or a derivative of a polyetherketoneketone, and the component is adapted for use in a downhole tool.

Abstract: A molded object is manufactured by a process, comprising:

Abstract: A method of reducing the restrictions of mixing fiber reinforced plastic includes the step of first coating the fiber. The coating is of a sort which will prevent the fiber from beginning to absorb the plastic such that the combined plastic and fiber may be stored for a period of time. Once the combined fiber and plastic are moved towards a mold, a mix station preferably cracks the coating. This allows the fiber to absorb the plastic matrix. The combined fiber and plastic is then delivered into a mold. By allowing the fiber to be pre-mixed with the plastic, the requirement of a “mix room” for mixing fiber into a plastic matrix adjacent to a molding facility is eliminated.

Abstract: A method of making an injection molded article, including the steps of: mixing at a temperature of at least 100° C. polymeric materials having a thermal conductivity in the range of 0.001 to 0.01 cal/cm-sec-° C. wherein the polymeric materials are selected from the group consisting of polyethylene, polystyrene, polyester, and polycarbonate or combinations thereof, and one or more materials selected from the group consisting of ceramics, ceramic composites, metals and metal alloys in a blended relationship to form a viscous phase mixture, the materials in the viscous phase mixture being selected so that when in a solid phase it has a density greater than 4 grams/cc and a thermal conductivity greater than 0.101 cal/cm-sec-° C. to form a feedstock; cooling the blended viscous phase mixture to form the feedstock; and using the feedstock in an injection molding machine to form the article.

Abstract: The invention relates to a process for producing mouldings by injection moulding, the steps in the process being

Abstract: A mold for producing molded fluoroelastomer parts has a mold cavity, a gate, and a runner and a sprue through which the gate communicates with an injection molding machine wherein an inorganic filler-containing crosslinkable liquid fluoroelastomer composition is injected into the mold cavity through the gate. The gate portion of the mold is surface treated with diamond-like carbon and has a cross-sectional area where it opens out into the mold cavity of 0.075-10 mm2. This combination of features lowers wear at the mold gate, thereby increasing the useful life of the mold, and also improves the mold release properties.