Abstract: The invention relates to a method and an apparatus for injection molding parts, which comprises a mixture of at least one plastic material and at least one additive in the form of fibrous or powdered fillers or reinforcement materials.

Abstract: A composite that includes a reaction injection molded matrix into which carbon fibrils have been incorporated, and a molding composition suitable for preparing such a composite. The invention also features a composite that includes a premix in which carbon fibrils have been incorporated into a resin matrix, and the molded product of the premix.

Abstract: Compositions having improved gas/vapor barrier qualities are described. The compositions are composed of a substantially non-polar resin and a lamellar filler, the lamellar filler delaminating under high shear, to increase its aspect ratio. Also described are compositions composed of a non-polar thermoplastic resin filled with platelets of talc having an aspect ratio of at least 5; the platelets have an average aspect ratio of between 16-30 and a CIE whiteness index of at least 40.

Abstract: A method of making an injection molded article having a marbled appearance, including the steps of: mixing at a temperature of at least 100 degrees ° 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 having a zero compression screw to form the article.

Abstract: A method of making a feedstock for injection molding, 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. and; cooling the blended viscous phase mixture to form the feedstock.

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. % polymer. The mixture is heated to its melting temperature and then injected into a mold. The mixture is cooled so as to form the cutlery. The cutlery is ejected from the mold.

Abstract: Filler-containing molded parts or articles are produced from a free-flowing reaction mixture, e.g. of polyol and isocyanate, in a manner which permits the changeover to a different filler content to be carried out more rapidly and, possibly, without material loss. This is achieved by dividing at least one of the reaction components into at least two portions, at least one of which is charged with filler, by adjusting the mixing ratio of these portions and hence the filler content of the finished molded part. At least two storage vessels are provided for at least one of the reaction components. Adjustable metering devices are arranged between these two storage vessels and the mixing device.

Abstract: An injection-molding process using warp-free pigment compositions including diaryldiketopyrrolo[3,4-C]pyrroles to improve the dimensional stability of the injection molded product by decreasing warping wherein the constituents of the formulation being injection molded are added into an injection molding machine in ready-premixed form or simultaneously as individual components. Preferred pigments are quinacridone pigments, disazo condensation pigments, isoindolinone pigments and pyrrolo[3,4-C]pyrrole pigments with pyrrolo[3,4-C]pyrrole pigments being especially preferred.

Abstract: I have developed an agglomeration process by which granules are formed by the steps of:

Abstract: A method for making a shaped article or a shaped article having a volume resistivity of less than 102 ohm-cm with a desired combination of properties and processibility in an injection moldable composition. In particular the shaped articles formed include injection molded bipolar plates as current collectors in fuel cell applications.

Abstract: A process for the preparation of fiber-reinforced plastic molding includes (1) shortening the fibers to a length of less than 30 mm; (2) introducing the fibers and the plastics present in the solid state, separately from one another, into a mixing chamber of a die press, wherein the plastic is in particulate form; (3) thoroughly mixing the plastic and fibers to give a solids mixture; (4) transporting the solids mixture through die orifices of the die press; (5) heating the solids mixture in the zone before or in the orifices of the die; (6) enclosing at least part or partly embedding the fibers by the plastic during or after the heating of the solids mixture; and (7) comminuting the granulated material for subsequent molding.

Abstract: Molding compositions including low molecular weight polyhydroxyalkanoates are provided. The use of the low molecular weight polyhydroxyalkanoates as a binder in molding compositions provides improved binder removal in the finished molded product, and offers a wide range of physical properties suitable for use in a variety of processing conditions. The composition preferably includes a powdered material, such as a metal powder, ceramic powder, or blend, admixed with a low molecular weight polyhydroxyalkanoate binder. The compositions are useful in powder processing techniques, such as injection molding, slip casting, tape casting, or extrusion. Methods of forming low molecular weight polyhydroxyalkanoates are also described.

Abstract: Plastic moldings reinforced with long fibers are made without the risk of forming loops in a continuous thread or roving fed to a cutting unit at the end of a mold filling operation or tearing thereof during renewed start-up for the next molding filling operation, even at a relatively high take-off speed of the continuous thread. This is achieved by keeping the continuous thread permanently under tension pneumatically against the conveying direction. The device useful for carrying out this process is equipped with at least one tensioning air inlet in the guide for the continuous thread or roving.

Abstract: The invention concerns a coating for a smoothing and/or polishing element, particularly a flexible grinding wheel, provided with a flexible abrasive insert, for smoothing and polishing stone material, comprising an epoxidic, comprising an epoxidic resin with poli-sulphuric polymers in a percentage between 34 and 52%, a product to make the mixture thixotropic, in percentage between 12 and 19%, primary amines, in percentage between 9 and 18%, and synthetic diamond, treated by a polyvinyl-formal primer.

Abstract: The present invention relates to new polyester compositions, novel processes to prepare molded articles from these new polyester compositions, and novel containers fabricated from polyester/clay composites for food and beverages. The processing methods employed in this invention enable containers to be formed which exhibit excellent clarity. Specifically, the present invention relates to a process comprising forming a parison from a composite composition comprising about 0.01 to about 25 weight % platelet particles dispersed in at least one polyester at a processing temperature which is at least 50° above the Tg of said polyester; and molding said parison into a clear, thin walled article.

Abstract: Reinforced composites containing cellulosic pulp fibers dispersed in a matrix, wherein the matrix comprises a thermoplastic polymeric material melting above 180° C. and the cellulosic pulp fibers have an alpha-cellulose purity greater than 80% by weight. Methods of making and using the reinforced composites.

Abstract: A fragrant plastic container fabrication method including the first step of preparing fragrant grains by dipping 30˜35% by weight of homologous microporous plastics in 65˜70% by weight of fragrant oil for about 24 hours, the second step of mixing 10% by weight of the fragrant grains thus obtained with 90% by weight of polyolefin to form an injection molding material, and the third step of injection-molding the injection molding material thus obtained into fragrant plastic containers through an injection molding machine.

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

Abstract: The method uses color to determine the wear of the screw and barrel of the molding machine. The method measures the color and/or color variation to determine the wear. A first material of a first color and a second material of a second color are fed into the machine to create a third material with a third color. The third material is either extruded to form a part or is injected into a mold to form a part. The color of the part is then measured with a measuring device, such as, spectrophotometer. The color will change as the screw and barrel wear. The color value would then be compared with previous color values to determine the amount of wear.

Abstract: Process for producing a composite article from a polyacetal (component a) with directly molded-on functional elements made from one or more thermoplastic elastomers (component b), and wherein components a and b have differing hardness, and the material with the greater hardness (component a) is initially premolded in a first step in a mold, and then is either cooled and removed from the mold and then placed into another, larger cavity, or is partially removed from the mold, but remains in a portion of the mold, and is then moved to a larger cavity, or, without removal from the mold, remains in the same mold, which is enlarged by means of a movable device, and in a second step, by overmolding with the material with the lesser hardness (component b), the molding formed from component a is firmly bonded to this material and is then removed from the mold as a composite article.

Abstract: The present invention is directed to a method for making a molded roofing unit formed of a fiber-reinforced plastic composition. In a preferred embodiment, the method comprises forming a camber in the roofing unit. The method of the present invention provides consistent results in the molding process, low material and production costs, and produces a roofing product with high rigidity and strength, impact resistance, stability in high wind conditions, and which is easy to install.

Abstract: The method of moulding plastics articles comprises propelling a solid plastics feed material by screw feed means (10) through a melting zone, the screw feed means (10) propelling the resultant molten plastics material to shaping means, shaping the molten plastics material in the shaping means and allowing the material to solidify to retain the shape, and is characterised by varying the composition of the plastics material cyclically before or along the length of the screw feed means (10) so that the molten material (1,2) emerging from the screw feed means (10) varies in composition with time, whereby at least one part of each moulded article (50) is of different composition from the remainder of the article (50).

Abstract: A method for laser marking one or more colors on a plastic substrate is disclosed. A polymeric blend or mixture comprising two or more polymeric systems is utilized to produce a molded component. The various polymeric systems are heated to form a polymeric blend or mixture that is in a molten flowable state. The polymeric mixture is then shaped into the desired end product, preferably by injection molding. While molding, the polymeric mixture separates according to the different densities of the polymers; with the lightest density polymers migrating toward the inner surface of the mold and the heavier density polymers centralizing within the interior of the mold. The lightest density polymer forms the outer surface of the molded product, which may essentially constitute an outer layer coating disposed around the other polymeric systems. Upon removal of the cured layered product, the skin layer is then preferably ablated using a laser to expose the polymers of desired color beneath the outer layer.

Abstract: The use of comminuted, recycled glass powders as a filler in molded plastic parts is disclosed. The recycled glass powder has non-uniform, rounded edges and is free from contaminants such as grinding compounds, metals, inorganic, and organic waste materials. The recycled glass powder filler can be used with a variety of different thermoplastics and thermosetting plastics commonly used to in injection molding and blow molding of plastic parts.

Abstract: The object of the present invention is to provide a colored resin composition having a uniform glitter feeling, which can prevent flow mark formation. In a resin composition molded by using a thermoplastic resin composition in which glitter material is mixed into a synthetic resin, said resin molded article must have a molding ratio L/T is not less than 100, wherein T is the thickness of the molded article and L is a distance from a gate position at molding to a remotest position on the molded article, and wherein said glitter material has average particle size d of 10 &mgr;m<d≦200 &mgr;m.

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: A plunger machine for molding reinforced polymer is provided. The plunger machine has particular application in molding polymer that is reinforced with particles having an aspect ratio greater than 1:1. The plunger machine includes a barrel housing with a smooth barrel bore that defines a main melt chamber. A plunger housing, having a plunger bore, defines an initial melt chamber that is in communication with the main melt chamber. A plunger resides in the plunger bore and is reciprocatable therein. The barrel bore is continuously inwardly to provide a smooth transition and alignment of reinforcing members in the polymer mixture during the melt process. The smooth bore ensures substantial alignment of the reinforcement members with the longitudinal axis of the bore to avoid excessive breakage of the reinforcing particles and prepare the polymer mixture for extrusion into a mold assembly.

Abstract: A novel process for preparing injection molding feedstock compounds in a continuous manner amenable to high volume manufacturing includes the steps of forming a mixture including metal and/or ceramic powders, a binder and a liquid carrier, supplying the components in a continuous manner to a twin screw extruder, forcing the homogeneous compounded mixture through an exit die, and cutting the extruded strand into pellets. The pellets are useful for shape-forming articles by various molding processes.

Abstract: The radiation shielding composition and method of the present invention relate to a conformal coating material composed of a matrix of densely packed radiation shielding particles, which are disbursed within a binder. The shielding composition is applied to objects to be protected such as integrated circuits, or to packages therefor, as well as for protecting animals including humans from unwanted exposure to radiation in outer space or other environments.

Abstract: A method for suppression of weld line weakening by virtually eliminating weld lines is disclosed. The process involves the near explosive injection of a metered amount of foamed thermoplastic molding material into an enclosing compartment formed by partly closing a compression type mold followed immediately by compression molding of the well mixed foamed material. The process finds particular utility in the manufacture of very long fiber reinforced parts. Variations on mold design and clamping cycles yield a variety of parts having foamed regions surrounded by more dense un-foamed regions. The method is particularly well adapted to the manufacture of large, very long fiber reinforced, foam-centered, hard surfaced, light weight, rigid parts.

Abstract: A method of molding roofing shingles includes the steps of providing a compression mold having two mold bodies, and installing a mold insert in each of the two mold bodies. The surfaces of the inserts are shaped to correspond with the desired shape of a roofing shingle. A multiplicity of roofing shingles are molded using the compression mold. Each molding step includes charging the mold with a moldable material containing resin in an amount within the range of from about 10 to about 40 percent, and filler material in an amount within the range of from about 60 to about 90 percent, wherein the filler material subjects the inserts to wear by abrasion. The inserts in the mold are replaced when they are worn out, but this is done without replacing the mold bodies.

Abstract: A manufacturing method of a simulated wood product utilizing pulverized powders obtained from recycled building members as raw material, in which the building members have recycled wooden members made of wooden materials and resinous members made of resinous materials, the manufacturing method further including a mixing process for mixing the recycled wooden members, a pulverization process for pulverizing the mixed materials obtained in the mixing process to form pulverized powder, a kneading process for kneading the pulverized powders obtained by the pulverizing process, and a molding process for molding the kneaded materials obtained in the kneading process either by an extrusion or injection molding.

Abstract: This thermoplastic composition and process for making articles of the same includes a thermoplastic matrix that includes a resin and filler materials wherein the filler materials includes a combination of fibers, at least one lubricant, and thermally conductive material, for improving tribological performance of thermoplastic materials. In the alternative, a thermally conductive lubricant may be substituted for the combination of the lubricant and the thermally conductive material.

Abstract: Methods of making a graphite material are provided. A flexible graphite is ground into a powder. The graphite powder is mixed with a resin and the mixture is hot pressed. A second method of making a graphite material is provided where the graphite is ground into a powder; the graphite powder is soaked in a cryogenic liquid; the soaked graphite powder is then expanded; the expanded soaked graphite powder is mixed with a graphite powder; and the graphite powder mixed with a resin are hot pressed. According to a third method, the flexible graphite is ground into a powder; the graphite powder is soaked into a cryogenic liquid, the soaked graphite powder is expanded; and the expanded soaked graphic powder is ground into a fine powder. The resulting graphite powder is mixed with a resin. The graphite powder mixed with the resin is hot pressed. According to a fourth method, graphite flakes are soaked into an acid; the soaked graphite flakes are expanded; and the expanded soaked graphite flakes are precompacted.

Abstract: Improved covers for electrolytic capacitors, offering both durability and low extractability of halides by high temperature electrolytes, can be produced from molding compositions including thermoset polymers having low halide extractability, preferably based on materials such as phenolic resins, and nonporous fillers, the compositions preferably being essentially free of porous fillers.

Abstract: An apparatus and method for molding thermosetting polymers onto clothing. The apparatus includes at least one molding device, at least one polymer supply and a control system for controlling the operation of the molding devices and polymer supplies. The molding devices include die sets having an input member and a mold. The polymer supplies supply polymers for injection into the input members of the molding devices for use in molding three dimensional bodies of polymers onto substrates such as clothing.