Abstract: A method is provided for molding an article (10) that includes a polymer (100) such as an epoxy resin, reinforced by fibrous material (102) such as fiberglass which is embedded in the polymer material, especially for a hollow article such as a shell. The method includes placing spacers (42, 44) in a mold cavity (30), where the spacers conform closely to the cavity surface and leave a free, or empty volume (64) within themselves. Foamable material (60A) is placed in the free volume and allowed to expand and push the spacers toward the cavity walls while forming a foam core (70) within the spacers. The mold is opened and the spacers and foam core are removed. Next, the foam core is covered with an impervious layer and the fibrous material (72) is wrapped around the foam core. The foam core is placed back in the mold, with the fibrous material spacing the foam core from the walls of the mold.

Abstract: A die preparation and exchange method wherein dies to be inserted into an injection molding machine are electrically and fluidly heated prior to insertion so as to prepare the dies to make parts more quickly. The die exchange sequence wherein a first set of dies are removed from the machine and are replaced by a second set of dies has been changed from a generally serial sequence to a sequence wherein most steps are performed in parallel or simultaneously, greatly reducing the downtime associated with mold change.

Abstract: A method for producing a multilayer molded article having good feeling of touch without giving damages on a skin material at the vicinity of gate portions by fushion-bonding integrally a skin material to a core material using a horizontal mold clamping type injection molding machine which comprises steps of closing a movable mold so that a mold interval between the movable mold and a fixed mold is set to a predetermined distance after the skin material is set up in the cavity of a mold, starting injection and filling-up of a resin melt for a core material into the cavity of mold, retracting the movable mold with progress of injection and filling-up until the mold interval becomes a predetermined distance after lapse of a predetermined time from the start of injection, and clamping the mold again after the completion of the injecting.

Abstract: A coordinate loop garment hanger comprising a molded plastic hanger body having a hook receiving loop element depending from and molded integrally with the molded plastic body at a lower portion thereof. The hook receiving loop element includes a passageway for selectively receiving and suspending therefrom a hook of a second ganged garment hanger which is at least partially enclosed along its length by left, right, top and bottom surfaces. In one embodiment, the left, right, top and bottom surfaces define substantially parallel left and right sides and rounded and curved top and bottom surfaces. The passageway is also curved along its length, with the open ends thereof being slightly lower than the center thereof. Several different embodiments of the loop element are disclosed with different length and shape sides, bottoms and ends.

Abstract: A roof rail in which a rail portion and a plurality of leg portions are integrally molded by use of a mold having a fixed or movable dam provided in a mold cavity, and which is formed of a polyamide resin composition containing a polyamide resin having a crystallization temperature of not higher than 210° C. and a glass transition temperature of not higher than 70° C. and glass fiber, wherein the difference in surface gloss between the surface of the rail portion and the surface of the leg portion is not higher than 5, and the difference in surface roughness between the surface of the rail portion and the surface of the leg portion is not larger than 0.5 ?m.

Abstract: The present invention involves a molded seamless vehicle interior panel having a seamless airbag door for concealing an airbag. The panel includes a retainer portion and a door portion circumscribed by the retainer portion. The retainer portion is disposed adjacent the airbag of the vehicle and has an opening to define a void over the airbag. The retainer portion has an appearance finish of an aesthetic look. The door portion disposed within the void integrally circumscribed by the retainer portion to define the seamless airbag door through which the airbag may deploy. The door portion has an appearance finish compatible to the appearance of the retainer portion such that no seam is visible. The door portion is molded together with the retainer portion and formed of a material different than the material of the retainer portion.

Abstract: An injection moulding apparatus for hollow parts comprises first and second co-operating dies, each die including a first male die core and a female die recess. One of the dies is rotatable about an axis. In a first angular position of the rotatable die, the male die core of the first die co-operates with the female die recess of the second die and the male die core of the second die co-operates with the female die recess of the first die, to define first and second moulds in which half-components may be formed. In a second angular position of the rotatable die, the respective female dies recesses of the first and second dies co-operate to form a third mould in which the half-components may be joined. The apparatus makes use of a single injector differentially controlled for each stage.

Abstract: During injection molding of a plastic product having a base wall and a sidewall, alignment of the mold parts that shape the mold cavity is maintained by conducting injected plastic material through a sequence of variable-opening throttles in a base-wall-section flow guide of the mold cavity. The openings of the throttles vary in response to variations in the thickness of a region of the sidewall section into which injected plastic material is conducted from the base-wall-section flow guide so that upon an increase in the thickness of such region the openings of the throttles in the base-wall-section flow guide decrease and so that upon a decrease in the thickness of such region the openings of the throttles in the base-wall-section flow guide increase.

Abstract: An object of the present invention is to provide a method of double color-molding a key top that is superior in design. In order to achieve this object, according to the method of double color-molding a key top provided in the present invention, at a first shot, a light-permeable resin layer is injection-molded, and simultaneously, a convex portion that corresponds to a planar shape of a closed loop in a letter, figure, sign, etc., is formed on a back surface of the light-permeable layer. In a second shot, a light-shielding resin layer is injection-molded on both an outer region and an inner region which are defined by a convex pattern of the convex portion on the back surface of the light-permeable resin layer. Since a gate trace, which remains after performing the gate-cut on the light-shielding resin layer, resides inside the key top, it is invisible from the outside of the key top. In this way, the design of a key top can be improved.

Abstract: A molding die includes an upper die, upper-die pins arranged in the upper die to be movable up and down, springs arranged in the upper die to urge the upper-die pins downwardly, a lower die, lower-die pins arranged in the lower die to be movable up and down and springs arranged in the die to urge the pins upwardly. In molding, a hollow primary molded piece is accommodated in a cavity defined by the upper die and the lower die. Then, the piece is mounted on the pins with retained apart from a concave bottom surface of the lower die. Before closing the molding die, it is started to inject molten resin into the cavity. As a result, the molten resin enters a space between the primary molded piece and the concave bottom surface of the lower die. Even after completing to close the molding die, the injection of the molten resin is continued.

Abstract: A method for molding an optical attenuator having a unitary lens portion and supporting portion includes the steps of: providing a mold having cavity and core elements which together define a space in which the optical attenuator can be molded including a movable core pin having a proximal end defining a surface of the lens portion, and a core pin motor coupled to the core pin for adjusting the thickness of the lens portion; injecting a suitable polymer into the space to form the optical attenuator; separating the cavity and core elements to extract the optical attenuator from the mold; optically measuring the thickness of the lens portion; and providing a signal indicative of the thickness of the lens to a controller having an output coupled to the core pin motor, the controller providing a signal to the core pin motor specifying any movement necessary to retain the thickness of the lens portion within a desired range before repeating the injecting step.

Abstract: In a method for producing flat molded plastic parts, for example panes, a mold is first filled completely with plastic material and additional plastic material is subsequently added, in such a way that the mold distends in a defined manner in opposition to the clamping force. The distension compensates for material shrinkage during a subsequent cooling operation, thus preventing sink marks and permitting the production of, for example, panes of high optical quality.

Abstract: An apparatus and method for molding multi-material parts. The mold has a plurality of first mold cavities interspersed alternately among a plurality of second mold cavities. A first molten material is injected into the first mold cavities and solidified. Cores with the first material are moved only one mold pitch to the second mold cavities where a second molten material is injected and solidified with the first material to form the multi-material parts which are ejected from the mold when it is opened. In one embodiment, cavities and cores are arranged in a column, and dummy cores on each end of a column of cores close off the injection nozzle in an end cavity from which a core has been removed for a molding cycle. In another embodiment, cavities and cores are arranged radially, and cores are rotationally moved one mold pitch with each molding cycle.

Abstract: Represented and described are a method for the manufacture of a reclosable pouring element and a pouring element manufactured in accordance therewith, whereby the pouring element features a basic body (1) and a closure cover (2), and whereby the closure cover (2) is connected in jointed fashion to the basic body by means of two bearing pivots (4).

Abstract: A method of molding a layer of a thermoset or thermoplastic material around a golf ball component within a mold, in which the component is positioned within a mold cavity defined by opposing mold portions of the mold, to leave a cavity space between the component and the mold portions. A reaction mixture comprising at least two reactants is injected under a hydraulic pressure into the cavity space. The pressurized reaction mixture pushes the mold portions apart from each other to a partially open position with an opening therebetween. The reaction mixture is allowed to react partially within the cavity space, and then the mold portions are compressed toward each other to the closed position. The reaction mixture further reacts to form the layer of the thermoset or thermoplastic material immediately about the component.

Abstract: A process for injection-foaming a thermoplastic resin by using an injection molding machine with a two-stage-compression screw, injecting a physical foaming agent into the cylinder of the machine at a pressure lower than the storage pressure of the physical foaming agent, mixing it with a melted resin and expanding the volume of the cavity of the mold at the time of injection, and an injection molding machine and resin composition suitable therefore.

Abstract: A disk-shape resin molded article such as a gear comprises a rim, a boss, a web having a disk configuration for connecting the rim and the boss, and gear teeth formed on the rim. The molded article is produced by an injection-compression molding process which comprises injecting a molten resin into a cavity of a metal mold, and pressing a web site and at least one site selected from the group consisting of a boss site and a rim site in a thickness direction. The cavity may have a capacity larger than the solidified products by contraction amount of the injected molten resin.

Abstract: The present invention comprises the formation of photonic polymer-blend structures having tunable optical and mechanical properties. The photonic polymer-blend structures comprise monomer units of spherical microparticles of a polymer-blend material wherein the spherical microparticles have surfaces partially merged with one another in a robust inter-particle bond having a tunable inter-particle separation or bond length sequentially attached in a desired and programmable architecture. The photonic polymer-blend structures of the present invention can be linked by several hundred individual particles sequentially linked to form complex three-dimensional structures or highly ordered two-dimensional arrays of 3D columns with 2D spacing.

Abstract: An injection compression molding method for injecting and compressing molten resin to obtain molding product using a molding die internally having a lens-forming cavity includes a pair of relatively movable inserts; a gate; a runner; and a sprue. The molten resin is injected and filled into the cavity and volume of the cavity is reduced by moving one insert toward the other insert after a time period prior to completion of injecting and filling the molten resin. At the time, a gate shut pin is protruded into the gate in synchronization with the movement of the insert to gradually close the opening of the gate. Accordingly, two demands, i.e. lower resistance in filling the cavity with the molten resin and shutting in the molten resin after the molten resin is packed in the cavity, can both be satisfied. This improves productivity and enables the production of mold products having highly accurate configuration and high quality.

Abstract: A procedure for sequential molding of an assembled object and a machine for the performance of the procedure are provided. A mold has a stationary front part, a movable back part and at least one turnable middle part. After the molding of the first part of an object, the middle part is turned at least once around an axis orthogonal to the moving direction between the front part and the back part, before the molding of the following part of the object takes place. Injection and cooling can take place in the front part and in the back at the same time. In an alternative embodiment, the middle part can be fitted with insulation to maintain a higher temperature between different regions of the mold assembly, making it possible to mold together considerably different materials such as a thermo plastic material and an elastomer, a silicone, or metal and plastic.

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: A method for manufacturing a modular plate for a cockpit-type instruments panel includes molding a modular plate having an outer peripheral rim and a plurality of apertures in a first shot of an two-shot injection molding process, and then overmolding a plurality of seals about the outer rim and at least one aperture during a second shot of the two-shot process.

Abstract: There is provided a process for producing a light transmitting plate comprising the steps of:

Abstract: A vehicular lamp and injection mold and manufacturing method for lamp bodies for producing a plurality of different types of vehicular lamps while resulting in a reduced cost of manufacturing due to sharing of a common injection mold. A lamp body of a tail lamp, for example, includes a reflective surface for reflecting light from a light source bulb forward and is formed with a bulb attachment hole for mounting the light source bulb constituted by an insert-molded surface. That is, part of a reflective surface of the lamp body is formed by an insert-molded surface molded with a cavity surface of an insert constituting a part of a fixed mold of an injection mold. To change to molding a different type of lamp body, it is only necessary to change the insert.

Abstract: A die preparation and exchange method wherein dies to be inserted into an injection molding machine are electrically and fluidly heated prior to insertion so as to prepare the dies to make parts more quickly. The die exchange sequence wherein a first set of dies are removed from the machine and are replaced by a second set of dies has been changed from a generally serial sequence to a sequence wherein most steps are performed in parallel or simultaneously, greatly reducing the downtime associated with mold change.

Abstract: Method for manufacturing injection molding pieces consisting of at least two components whereby a first injection molding piece is formed of a first component in a first mold impression and a second injection molding piece is formed by putting the first injection molding piece in a second mold impression, and by providing a second component on it, characterized in that a mold with at least three series of mold parts is used, whereby the first series and the second series thereof alternately work in conjunction with the third series, and whereby a mutual repositioning of every first injection molding piece takes place in between.

Abstract: A tear portion is formed at a substantially center portion in a longitudinal direction and at both end portions in a lateral direction of an air bag door portion of an instrument panel so as to be formed in an H shape in a plan view. In the air bag door portion, protrusions are protruded downward at positions at both sides in a longitudinal direction of an automotive vehicle having therebetween a center portion of the tear portion, these protrusions being integrally formed with the air bag door portion. Accordingly, it is structured such that during expansion of the air bag body, the expanding air bag body abuts lower surfaces of the protrusions, so as to press the protrusions upward. Therefore, even in a case wherein the air bag door portion and the main body portion of the trim member for the automotive vehicle are formed of the same resin, a quality of an outer appearance is not deteriorated, and a break force of a break portion of the air bag door portion is reduced to a desired value.

Abstract: Injection-moulding machine for producing plastic containers, comprising an upper platen (1), a moving mould-carrying platen (2), a support bar (3) for lips constituted by two respective separable members (15a, 15b), a plurality of male members (6) applied to said upper platen (1), a cavity-carrying platen (4) in which there are provided removable means (16) adapted to delimitate the travel of said moving mould-carrying platen (2) towards the cavity-carrying platen (4), so that the moving mould-carrying platen (2) can be positioned at a pre-selectable distance with respect to the cavity-carrying platen (4). Said removable means (16) are referably constituted substantially by a number of resting cylinders, or parallelepipeds, arranged parallel with respect to each other and having the same height, the axis of which is parallel to the moving direction of the moving mould-carrying platen (2).

Abstract: A process is provided for producing a foamed article of a thermoplastic resin composition having a relatively thicker solid skin layer exhibiting better appearance without occurrence of a swirl mark and having a foam structure of relatively uniform foam cell size with better foam cell configuration, which is light-weighing and superior in stiffness, in an easy and efficient manner, by causing the resin composition to foam up in a cavity of a mold.

Abstract: Methods are provided for manufacturing an antiperspirant or deodorant product within a container, the product having an application surface that includes first and second portions having different compositions. The methods generally include (a) delivering to an open end of the container, through a first delivery nozzle, a first composition that will form the first portion, and, through a separate second delivery nozzle, a second composition that will form the second portion, the first and second compositions being in molten form during delivery, (b) providing a barrier between the first and second compositions to prevent intermingling thereof, (c) allowing the first and second compositions to solidify to form the product; and (d) removing the barrier.

Abstract: An injection-compression molding apparatus includes a stationary mold provided with a nozzle for injecting molten resin, and a movable mold driven by a servo motor. In compressing the resin, high-speed position control of the movable mold is first performed, which is then switched to speed feedback control which enables delicate regulation of clamping pressure in accordance with pressure fluctuations in the resin.

Abstract: A window 30 is a two-color molding comprising a transparent section 32 and a frame section 31 integrated with the transparent section 32, the frame section 31 and the transparent section 32 are formed with a first material and a second material respectively, and the first material is a thermoplastic resin with the linear thermal expansion coefficient in the MD direction lower by 1×10−5 to 3×10−5 (mm/(mm.K)) than that of the second material, and also with the MD/TD ratio for the linear thermal expansion coefficient in the range from 0.6 to 1.

Abstract: An apparatus for adjusting die stroke includes a plurality of adjustable helical springs, each of which is equipped with a displacement sensor, a rotation sleeve, and a rotation sleeve driver; a plurality of supporting rods; and a central processing unit. The apparatus is mounted between an oil-pressure cylinder and a top die movable above a bottom die. After the top and the bottom dies are closed to each other, deformation of the adjustable helical springs detected by the displacement sensors and errors measured at different points of molded product released from the dies are sent to the central processing unit for operation. Based on operation results, the central processing unit sends adjusting signals to the rotation sleeve drivers for the same to turn the rotation sleeves and thereby adjusts the helical springs to required modulus of elasticity for use in next cycle of molding process to reduce product errors.

Abstract: A method of integrally forming shoe with multiple material employs a set of molds which include a lower mold, a middle mold and an upper mold. The lower and middle mold have respectively a lower cavity and a middle cavity. The method includes the steps of: blending, melting and injecting, secondary injecting, positioning and pouring. The contact surface of the outsole will be melted slightly when a coupling agent is injected thereby to bond the TPU and outsole made from rubber. A vamp may be placed over the middle mold to receive the PU for forming a midsole thereby to enable the vamp, midsole and lower sole formed integrally.

Abstract: A moulding method, carried out by a mould for a conventional injection press, suitable for cost-effectively realising a piece in one or more injectable materials, the mould comprising a mobile part and a fixed part, on such mobile and fixed parts being realised respective impressions, which define, when the mobile part is closed against the fixed part, recesses suitable for receiving the injectable materials in at least two successive injection steps; the method comprises a step of housing a sliding element in at least a first recess, a first injection step in such a first recess, after which a first part of the piece remains fixed on a surface integral to such a sliding element, a displacement step of such a first part of the piece in a second recess and then a second injection step in such a second recess.

Abstract: A method of forming a two-piece assembly, such as a container closure assembly, in which a spout member is movable on a chimney section defined by a chimney member, which is adapted to be engaged with the neck of a container for dispensing the container contents. The spout member is formed in a first mold cavity, and includes a side wall and an end wall with an opening. The first cavity is defined by first and second mold sections, and the second mold section is removed after the spout member is formed. The second mold section is then replaced by a third mold section, which cooperates with the first mold section and the spout member to form a second cavity having a shape corresponding to the chimney member. The second mold section and the side wall and end wall of the spout member cooperate to form the chimney member with a side wall and end wall which overlie the spout member side wall and end wall, respectively.

Abstract: An injection moulding process for making a moulded article particularly a toothbrush consisting partly of a hard first plastics material by providing a first injection mould introducing a component into the cavity adjacent to the surface; injecting a plastics material into the cavity so that the plastic material is fixed to the component and the component forms part of the outer surface of the article. In a second moulding operation another material such as an elastomer may be injected. A toothbrush product made by this process is also described.

Abstract: In an injection compression-molding apparatus, a molded article is produced by setting molds 10 and 11 to an intermediate clamped state, and then by setting the molds 10 and 11 to a final clamped state by re-clamping the molds 10 and 11 to each other after injecting melted resin into a cavity defined by the molds 10 and 11. The apparatus includes a clamping mechanism and a parallelism retaining mechanism 20. The clamping mechanism has a mold-driving cylinder 7 for moving the movable mold 10 toward and away from the fixed mold 11, a guide engaging member 8, support panels 4, 5, etc. so as to selectively set the molds 10 and 11 to the intermediate clamped state and the final clamped state. The parallelism retaining mechanism 20 retains parallelism between the molds 10 and 11 in the intermediate clamped state by giving a corrective force to mold attaching surfaces of the clamping mechanism where the respective molds 10 and 11 are mounted.

Abstract: The invention discloses a sheet-like structure material and its manufacturing method. The sheet-like structure material has the advantages that impact imposed on its edge ends can be adsorbed to protect its adherends, and that the labor required for installing it and edge ends treatment can be significantly saved. The structure material comprises an outer peripheral structure which has elasticity and is integrally formed at the outer periphery of a sheet-like composite body comprising two glass sheets and an intermediate resin layer disposed between the glass sheets. The outer peripheral structure is formed from a resinous material used for forming the intermediate resin layer, by allowing the material to ooze from between the glass sheets.

Abstract: A molded article includes thermoplastic resin, and an organic material different from the thermoplastic resin inside said molded article, the organic material being located on and near a surface of said molded article.

Abstract: A process for producing an exterior member/seal member assembly includes: a first step of moving a slide core to protrude into a major cavity defined between first and second dies and, and injecting a hard synthetic resin into an exterior-member forming cavity partitioned in the major cavity; and a second step of retracting the slide core and injecting a soft synthetic resin into a seal-member forming cavity which is a remaining portion of the major cavity. An outer-seal-lip forming portion is connected to an outer end of the seal-member forming cavity; a recess-shaped step is formed on one side face of the slide core and adapted to define an inner-seal-lip forming portion leading to the seal-member forming cavity between the step and an inner surface of a guide bore in the second die when the slide core is retracted; and the soft synthetic resin is filled into the outer and inner-seal-lip forming portions 15 and 16 at the second step.

Abstract: A latching device (20) for a mold assembly (10) uses a cam action to hold the “A” side plate against the hot runner system/nozzle plate (18) during operation. Preferably, a latch (20) is provided on each side of the mold to effectively hold the “A” side plate against the nozzle plate (18) during the high pressure injection of plastic melt. For purposes of a mold insert change, each latch (20) is rotated to release the “A” side plate from the nozzle plate (18), and hold the “A” side plate against the “B” side plate. This enables the “A” (12) and “B” (14) portions of the mold assembly to be moved away from the nozzle plate (18), thereby avoiding interference of the hot runner nozzles and “A” side insert and enabling quick mold insert change.

Abstract: A method of manufacture of high optical quality transparent plastic for use as a mirror or glass substitute.

Abstract: The invention concerns a method for sequential moulding with multiple materials for making a piece comprising at least two parts with matching shapes produced in a different plastic material, mobile relative to each other by pivoting about a hinge, which consists in: using a moulding equipment comprising a second mould (30) and a first mould (31) whereof the assembled impressions define the cavity of the open part, the mobile portions forming between them an angle of about 180°, one of the moulds (31) comprising a housing wherein slides a gate (35), capable of blocking the flow of the first plastic material; injecting the first portion (32, 34) with a first plastic material, the gate (35) providing with its side wall an obstacle to the flow of said first plastic material at the fasteners of the elements of the hinge on the second piece; causing the gate (35) to open and injecting the second plastic material into the second portion (33) of the piece.

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: In an injection compression molding apparatus and an injection compression method according to the present invention, the structure of the dies can be simplified and a loss of resin as well as of heat due to solidification of the resin in the path at the time of molding can be eliminated. Further, injection pressure loss can be reduced when melted resin is injected into a cavity. A resin injection hole in a nozzle that is attached to an injection device is connected at a position between a stationary die and a movable die directly to the cavity that has a larger volume than a volume of a molded product by means of the movable die, melted resin is injected into said cavity directly from said resin injection hole by said injection device, then the movable die is moved, in the die closing direction, to reduce the distance of the connection between said resin injection hole and said cavity by means of a side wall of the movable die, and to reduce the volume of the cavity so as to compress said melted resin.

Abstract: The invention relates to a method and apparatus for making thick-walled plastic parts, in particular blanks for optical lenses. In accordance with the invention, a two-phase production process is proposed in order to make thick-walled lenses with high optical quality and homogenous material properties, wherein in a first phase, a thin lens is first made through injection molding, and in a second step the lens is enlarged, i.e. “inflated”, until the final thickness through continued injection of plastic material.

Abstract: A method of this invention is an injection compression molding method of molding a thin molding, using an injection compression molding machine including: a pair of a movable mold and a stationary mold defining a molding space; a movable die plate on which the movable mold is mounted; a stationary die plate on which the stationary mold is mounted; an injection unit for injecting a molding material into the molding space; and a mold clamping unit for causing the movable die plate to move toward and away from the stationary die plate, capable of controlling a clamping pressure for pressing the movable die plate toward the stationary die plate while the injection unit is injecting the molding material into the molding space. This method includes a nonloaded flow step of controlling the mold clamping unit in such a manner that any resistance is not exerted substantially against flow of the molding material injected into the molding space by the injection unit, during the injecting step.

Abstract: The mold comprises:

Abstract: A method of forming a two-piece assembly, such as a container closure assembly, in which a spout member is movable on a chimney section defined by a chimney member, which is adapted to be engaged with the neck of a container for dispensing the container contents. The spout member is formed in a first mold cavity, and includes a side wall and an end wall with an opening. The first cavity is defined by first and second mold sections, and the second mold section is removed after the spout member is formed. The second mold section is then replaced by a third mold section, which cooperates with the first mold section and the spout member to form a second cavity having a shape corresponding to the chimney member. The second mold section and the side wall and end wall of the spout member cooperate to form the chimney member with a side wall and end wall which overlie the spout member side wall and end wall, respectively.