Abstract: The subject technology is related to methods and apparatus for discretization and manufacturability analysis of computer assisted design models. In one embodiment, the subject technology implements a computer-based method for the reception of an electronic file with a digital model representative of a physical object. The computer-based method determines geometric and physical attributes from a discretized version of the digital model, a cloud point version of the digital model, and symbolic functions generated through evolutionary algorithms. A set of predictive machine learning models is utilized to infer predictions related to the manufacture process of the physical object.

Abstract: A process for making a reservoir including steps of positioning a hollow extrudate at an elevated temperature in a mold cavity, inserting a fitting into an end of the extrudate, sealing an outer surface of the fitting with an interior surface of the extrudate using latent heat within the extrudate, and forming at least a portion of the extrudate against the mold cavity forming a reservoir with the fitting sealed into the reservoir.

Abstract: A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of rib members forming a grid pattern on the first portion and another plurality of rib members extending toward the periphery of the first portion which may be non-orthogonal to each other and to the rib members forming the grid pattern. A tubular cavity may be formed within each of the non-orthogonal rib members by injecting a gas into the rib member during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.

Abstract: The invention relates to a medicament container, comprising a cavity at least partially defined by a container wall comprising a soft, flexible inner layer consisting of a soft material and a rigid outer layer consisting of a rigid material, wherein the layers are arranged as a one-piece part by two component injection molding.

Abstract: The invention described herein relates to a method by which a reservoir having desired end connection profiles may be made using shape memory characteristics of crosslinking to compressively seal the connection profiles into the reservoir.

Abstract: A composite interbody device includes superior and inferior endplates with a plastic core molded therebetween. The core includes one or more features for permitting bone growth through the core. Each endplate includes a bone interface side coated with hydroxyapatite, for promoting bone on-growth. Pores in the bone interface sides permit bone in-growth. Core interface sides of the endplates include relatively larger pores for accepting molten material from the core, for example during injection molding, to enhance bonding of the endplates with the core. Each endplate has a central barrier layer for preventing the molten core material from extruding through the core interface pores into the bone interface pores, reserving the bone interface pores for bone in-growth. A method of manufacturing the composite interbody device is also disclosed.

Abstract: The present invention provides a method for producing an injection molded panel member having a first portion, a second portion, and an appearance surface portion. The method includes placing the appearance surface portion of the panel member into a mold cavity. The mold cavity preferably includes a first chamber adapted to form the first portion of the panel member, and a second chamber adapted to form the second portion of the panel member. After the appearance surface portion of the panel member is inserted into the mold, molten plastic material and pressurized gas are injected into the first chamber of the mold cavity. After the molten plastic material is injected into the first chamber of the mold, molten plastic material is injected into the second chamber of the mold cavity. The molten plastic is then cooled until it solidifies. After the molten plastic is sufficiently cooled, the pressurized gas is vented and the panel member is removed from the mold.

Abstract: A carpule and its method of manufacture, the carpule tubular body composed of a polypropylene or similar polymer, the tubular body being sealed at one end by a seal of a thermoplastic vulcanizate (TPV) or similar polymer, the seal having been injection molded in contact with the tubular body prior to full curing of the material composing the tubular body, such that a chemical fusion bond is created between the seal and the tubular body.

Abstract: Provided are an apparatus and method for synthesizing a conductive composite with enhanced electrical conductivity. The apparatus includes: an injection-molding machine which injection-molds pellets created by mixing carbon nanotubes (CNTs) with polymers; and an electric field generator which applies an electric field to the pellets that are melted while the melted pellets are injection-molded and thus rearranges the CNTs included in a composite into which the melted pellets are injection-molded.

Abstract: The present invention relates to a connector of an electromagnetic clutch for a compressor and a manufacturing method thereof. The method includes the steps of arranging a leading end of a lead wire 62 or 72 of at least one discharge device 60 or remaining magnetic field removing device 70, which configures a surge absorbing circuit, to a terminal 50 installed in a connector 30 configuring a field coil assembly and having a coupling slot 56 formed in one side thereof; plastically deforming at least one slot bridge 57 to fix the lead wire 62 or 72 to the coupling slot 56; and making the connector 30 in a state where the terminal 50 is fixed to an assembly of at least the discharge device 60 or remaining magnetic field removing device 70 by injection molding.

Abstract: An LED chip encapsulation process includes the steps of (a) forming a fluorescent member by injection molding to encapsulate an LED chip; (b) hardening the fluorescent member; (c) forming a transparent dome to embed and encapsulate the LED chip and the fluorescent member; and (d) securing the dome and the substrate together to finish a packaging of the LED chip. Shape of the fluorescent member disposed on the LED chip can be controlled precisely, thereby increasing quality and color uniformity of the produced LED chip. Alternatively, the LED chip is a remote LED chip and step (a) is replaced by forming a plastic member to encapsulate the LED chip and forming a fluorescent member on the top of the plastic member by injection molding.

Abstract: Disclosed is a lamp tube structure with reflective surface. In this invention, the lamp tube structure with reflective surface can be achieved by forming a reflective layer on the inner surface or outer surface through coating, plating, chemical vapor deposition, sputtering, evaporation deposition or pasting. The lamp tube structure with reflective surface can also be achieved by the assembling the parts with reflective surface in combination with the transparent lamp tube or lamp tube parts, in this invention. The incorporation of the reflective surface lets the lamp light be utilized more effectively, and it is helpful to energy saving.

Abstract: A back light unit and a manufacturing method thereof capable of improving efficiency of a manufacturing process are disclosed. The back light unit includes a light source, a light guiding plate which uniformly transmits a light beam generated by the light source, and a cover portion which forms an external appearance and fixes the light guiding plate, wherein a resin material is charged between the light guiding plate and the cover portion to couple the light guiding plate and the cover portion.

Abstract: A spread illuminating apparatus of side light type includes a transparent resin plate integrally composed of a light conductor plate portion and a housing frame portion, a light reflecting sheet, and a light source, wherein an opening for housing the light source is provided at a side portion of the transparent resin plate, slits are provided along a boundary between the light conductor plate portion and the housing frame portion, and wherein a gate for injecting resin into a molding die cavity for the transparent resin plate is positioned outside the boundary of the light conductor plate portion and the housing frame portion and is positioned also between the opening and one of slits which are provided toward the side portion of the transparent resin plate having the opening and which are located clear of the opening.

Abstract: A method for forming a protective jacket over a connection region includes connecting the leads of an electronic device to conductors such that the connections are in a connection region, placing the connection region in a mold, injecting molten protective material into the mold to cover the connection region, allowing the molten material to cool and harden and removing the connection area from the mold.

Abstract: A first customer provides a CAD file defining the surface profile for a part to be molded to the system, and a second customer does the same for a second part. The system determines whether the materials match and the run dates overlap, thereby qualifying the parts for use in a multi-customer mold block. The system assesses the part surface profile (which could have any of a virtually infinite number of shapes) of the parts submitted and lays out the parts from multiple customers on one or more multi-customer mold blocks. Savings are generated, such as by reducing redundancies in press clean-up, in set-up, in tooling, and in surface finishing. Due to these savings, the system provides a quotation of the part to at least one of the customers which differs from the quotation that would be provided if each part was run independent of parts of other customers.

Abstract: Toughened polyoxymethylene-poly(lactic acid) resin compositions comprising polyoxymethylene, poly(lactic acid), and an impact modifier comprising an ethylene copolymer impact modifier made from monomers (a) ethylene; (b) one or more olefins of the formula CH2?C(R1)CO2R2, where R1 is hydrogen or an alkyl group with 2-8 carbon atoms and R2 is an alkyl group with 1-8 carbon atoms, such as methyl, ethyl, or butyl; and (c) one or more olefins of the formula CH2?C(R3)CO2R4, where R3 is hydrogen or an alkyl group with 1-6 carbon atoms, such as methyl, and R4 is glycidyl. The ethylene copolymer impact modifier may further be made from carbon monoxide monomers. The compositions may further comprise one or more ethylene/acrylate and/or ethylene/vinyl ester polymers, ionomers, and cationic grafting agents.

Abstract: A magnetic disk with an embossed pattern is provided. The disk comprises a magnetic film formed on a substrate provided with an erose embossed pattern on a surface along a circumferential direction, said embossed pattern having an upper surface, a lower surface, and a inclined portion or a vertical portion between the upper surface and the lower surface. In the disk, at least the magnetic film in the inclined portion or the vertical portion of the embossed pattern is magnetized, the direction of said magnetization in the magnetic film in the inclined portion or the vertical portion in cross section in the circumferential direction of the magnetic disk is substantially parallel with a film surface of the magnetic film, and said magnetic film in the inclined portion or the vertical portion has a magnetization reversal area.

Abstract: The present invention is directed to a method of obtaining a gas-introduced fiber-reinforced resin injection molding and to a molding obtained by the method. According to the present invention, there can be obtained a lightweight gas-introduced fiber-reinforced resin injection molding containing glass fibers or like fibers having excellent rigidity and strength and improved surface properties.

Abstract: An extruded composite structural artificial lumber product is manufactured from wood fiber and polyethylene, including recycled polyethylene, by reducing the wood fiber and polyethylene each to a finely divided particles, mechanically mixing the wood fiber and polyethylene particles together with a measured amount of a powdered endothermic foaming agent, mechanically mixing the mixture, without pre-pelletization, in a twin-screw extruder where it is compressed and heated until it becomes plastic and homogenous, and then extruding the plastic mixture, using vacuum to remove vaporized moisture and other excess volatiles, through a molding die which forms structural profile of the desired product.

Abstract: A unique composite material impregnated with a heat curable resin comprising a layer of conductive fibers and one or more resin carrying layers is utilized to reinforce utility poles by wrapping the material around a portion of the utility pole and causing a current to flow through the conductive fibers to resistively heat the material to the resin. The composite material can also be incorporated into molds to produce cured composite parts. The composite material is also used in the construction of large parts without the need for huge, expensive molds. The conductive fibers in composite parts are oriented in a manner to ensure that the entire part is thoroughly heated during the curing process.

Abstract: A process for manufacturing an insulation board comprising a rigid polyisocyanurate foam core having two major surfaces and a facing material on at least one of the major surfaces, comprising (a) conveying a facing material along a production line for attachment to one major surface of the core; (b) applying a foam-forming mixture of polyisocyanurate to the facing material such that the mixture is applied along the entire width of the facing material; (c) optionally conveying a second facing material along the production line for attachment to the other major surface of the core; (d) conveying the facing material with applied foam-forming mixture into a laminator which comprises a gap for foam expansion and allowing the mixture to foam and expand to fill the gap within the laminator; and (e) curing the foam. The process provides excellent boardstock thickness control, minimal wasted densification at the foam/facer interface, greater compressive strength and high line speed.

Abstract: Insulative compositions are prepared by agitating an aqueous mixture of aerogel and gelatin. Insulation obtained with such methods is non-toxic, environmentally safe, fire resistant with low smoke, has good handling properties, and provides low thermal conductivities. The insulation can be made in sheets, loose fill, or can be molded into particular shapes to provide particular types of insulation such as pipe insulation.

Abstract: The present invention provides a process for producing alveolar cellulosic products (sponges, sponge-cloths, etc.) from a cellulosic raw material, the process comprising:at least partially dissolving a cellulosic raw material in an intrinsic solvent for cellulose;incorporating an effective quantity of at least one pore-forming agent into the resulting mixture, with mixing; said pore-forming agent(s), being compatible with the cellulosic mixture, being capable of generating macro- and micro-pores when it/they is/are actuated;gelling the homogeneous dough thus obtained;treating said gelled dough under conditions in which the cellulose precipitates out and the pore-forming agent(s) present are actuated.The process is an advantageous alternative to the viscose process which is a polluting process. The properties of the products obtained are completely similar to those of products obtained using the viscose process. The (novel) products form part of the invention.

Abstract: The present invention relates to a breathable, oriented microporous elastomeric film. The present invention also relates to a process for forming the breathable film including the step of stretching a filled film to produce a microporous film layer.

Abstract: A process for preparing microporous separating elements for batteries by intensive mixing of a high molecular weight polyethylene with a precipitated silica having specific chemical and physical characteristics, a process liquid and a stabilizer to form a powder mixture, which is extruded to form a film, from which the process liquid is removed, thereby leaving the desired microporous separating elements which are recovered.

Abstract: A method of producing a three-dimensional shaped plastic foam part comprises the steps of mixing plastic foam granules of a predetermined range of sizes and of different hardness in a predetermined mixing ratio to obtain a mixture of the plastic foam granules, mixing the mixture of the plastic foam granules with a liquid primary material until the granules are coated with the liquid primary material and a mixture of coated plastic foam granules is obtained, feeding a preset quantity of the mixture of coated plastic foam granules into a mold cavity of a mold closed on all sides, reducing the volume of the mold cavity at least in partial regions thereof after it has been filled with the mixture of coated plastic foam granules, triggering a reaction of the liquid primary material by applying pressure and heat until a continuous cellular structure of plastic foam has been formed and the plastic foam granules have been interconnected by the cellular structure of plastic foam after the volume of the mold cavity has

Abstract: The present invention relates to a process for producing a dispersion of polymeric microspheres in a polyol comprising expanding 1 to 70% by weight of polymeric beads in a polyol with a twin screw extruder to simultaneously mix and expand the beads to create a uniform dispersion of the microspheres in the polyol such that the wetting of the microspheres by the polyol is maximized.

Abstract: Disclosed are a polymer in the form of particles more than 1 .mu.m in size which contain more than one void, an aqueous dispersion comprising this polymer, processes for the preparation thereof and the use thereof.

Abstract: A foamed rubber composition for pneumatic tires comprises at least one diene polymer as a rubber ingredient and includes closed cells in a matrix rubber, each of these cells being covered with a coat layer made from a given amount of a resin or resin composite having a JIS-C hardness of not less than 75, a particle size of 10-200 .mu.m and a reacted conjugate diene unit content of not less than 10% by weight. In the production of the foamed rubber composition, the melting point or glass transition point of the resin or resin composite is restricted to at least 5.degree. C. lower than the vulcanizing temperature.

Abstract: An acoustic absorbing component comprising a fiber-reinforced thermoplastic resin expanded body having a percentage of void not less than 50 vol %, and a resin molded body. The fiber-reinforced thermoplastic resin expanded body is fused under a pressure to at least a part of a surface of said resin molded body.

Abstract: A pressure sensitive sparkless switching device includes a layer of piezoresistive cellular polymer foam, at least two conductive layers, and an insulative spacer element having at least one opening. When pressure is applied to the device the piezoresistive foam disposes itself through the opening of the spacer element and makes electrical contact between the conductive layers. The resistance of the piezoresistive foam varies with the amount of pressure applied to provide an analog as well as on-off function. The device may also provide multiple switching, and shear detection capabilities.

Abstract: A method of compression molding a closure having a base wall and peripheral skirt with internal threads, a thermoplastic resin blended with metallic particles wherein the particles are added in elliptical or spherical form. The metallic particles are provided in a carrier of resin which is then blended with the resin of the closure and the melt blend is extruded through a nozzle and cut into individual pellets. Each pellet is deposited into the cavity of a mold which is then closed to compression mold a closure.

Abstract: In order to improve the sealing property and the resistance to pressure of a gasket coated with foam rubber layers, the foam rubber layers are formed on both surfaces of a metal plate from a rubber which is swollen by the medium to be sealed by the gasket, e.g. a rubber having an oil swelling property such as an NBR, is used. In this way the sealing property thereof is improved.

Abstract: The invention relates to a process for the manufacture of new shaped parts, preferably made from chipboards, wherein a mass formed from at least a binder and a small-particled material brought into contact with this binder is subjected to extrusion at elevated temperature and pressure. In the process according to the invention, a mass possessing a total moisture content of 6 to 25 wt. % or adjusted to the stated moisture content and made up of at least one biopolymeric preferably starch-containing binder, which converts into a melt and/or gel at extrusion temperatures and pressures, and further made up of the small-particled material, is subjected to extrusion and immediately thereafter undergoes decompression and spontaneous expansion.

Abstract: A decorated shaped product having an expression or design applied thereto which closely resembles an actual expression of a source material such as a natural object is disclosed. The product includes a shaped base material formed thereon with a flow pattern and a transfer pattern of which at least a part is subjected to a concealment exposing treatment and which is printed on the shaped base material. Also, a method manufacturing the product and the shaped base material are disclosed.

Abstract: A wire harness includes a plurality of wires surrounded by a continuous molded sheath. The sheath includes a first section made of a first material and a second section integral with the first section and made of a second material different from the first material. The different materials provide different colors, such as for color-coding branches of the wire harness. The different materials also provide areas of increased abrasion resistance to mechanical wear, temperature resistance and chemical resistance.

Abstract: A process is disclosed for producing interior trims for transport means, in particular motor vehicles, that consist of a bearing dimensionally stable part and of a decorative part that forms the visible side of the interior trim. The bearing, dimensionally stable part is made of plastic materials stiffened by reinforcing inserts. In order to considerably improve the process, the plastic materials consist of natural or recycled polyols and isocyanates and a material made of natural fibers is used for the reinforcing inserts. The material made of natural fibres is laid into a heatable (foaming) mold whose shape corresponds to that of the interior trim to be produced, the reactive, foamable polyurethane mixture is injected into the mold at a dosing pressure from 100 to 300 bars, then foamed and hardened in the mold at a reaction pressure form 3 to 300 bars.

Abstract: A syntactic structural foam product in flat sheet form or curved three-dimensional form adaptable to such uses as a light weight structural core for composite laminates, is made of a mixture of hollow ceramic microspheres and dry resin powder, of either thermosetting or a high-temperature thermoplastic resin, distributed in the interstices of the mass of microspheres for integration of the mixture into desired form upon heating and cooling. The dry resin powder in an other embodiment of the invention includes unexpanded expandable powder which will expand into microballoons in the confined spaces in which they reside and effect a bonding relation with surrounding particles upon supply of heat to the mixture.

Abstract: A three-dimensional shaped part comprises at least one first portion having an equal density throughout the volume thereof and comprising a plastic foam of a primary material having a cellular structure and plastic foam granules interconnected by the cellular structure of the plastic foam, and at least one second portion having an equal density throughout the volume thereof, the second portion being adjacent the first portion and comprising a plastic foam of a primary material having a cellular structure and elastically precompressed plastic foam granules interconnected by the cellular structure of the plastic foam. 70% to 90% of the volume of the shaped part is formed by the plastic foam granules, and the density of the second portion is greater than the density of the first portion.

Abstract: A coating fluid holding member including a porous molded body which is formed of heat-resistant fibers (or a mixture of heat-resistant fibers and a filler) bound to each other with a binder, has intercommunicating pores having an average pore size of 1 to 500 .mu.m, and has a porosity of 20 to 90%, and a coating fluid holding member including a porous molded body which is formed of heat-resistant fibers bound to each other with a binder, contains fine intercommunicating interstices between fibers and uniformly distributed pores having a diameter of 0.05 to 2 mm, and has a porosity of 30 to 90%. The holding member has a high fluid holding capacity for its volume and releases the coating fluid, such as a parting agent, an oil or a coating compound, in a stable manner for an extended period of time.

Abstract: Composite products incorporating a polymer matrix, polymer microspheres, glass microspheres and natural fibers, particularly kenaf are described. The polymer microspheres are 15 to 50 microns in diameter and are smaller that the glass microspheres which are 50 to 200 microns in diameter. The polymer microspheres reduce voids and prevent cracking of the glass microspheres upon compression. The composites have low cost and high strength.

Abstract: A novel polyurethane foam is shown which uses ground vehicle tires as a filler material. A method of manufacturing a carpet pad using the novel polyurethane composition is also shown. A frame is provided to which is mounted a conveyor belt. The conveyor belt feeds a first liner having an exposed surface of the polyurethane foam along a conveyor path from a forward end to a rearward end. A foam spray assembly is connected to a conventional uncured polymeric foam supply having a spray nozzle mounted adjacent to the forward end of the conveyor path. The spray nozzle dispenses uncured, resilient polymeric foam as a generally uniform layer on a surface of the first liner of previously cured polyurethane. A second conveyor belt, parallel to the first conveyor belt, feeds a second liner sheet along the conveyor path so that the second liner sheet is positioned over the layers of foam laminate.

Abstract: A fiber-reinforced article includes an expanded core layer having opposing first and second surfaces with a thickness defined therebetween. The expanded core layer is formed from a composition comprising a thermoplastic material and fibers with average length of not less than about 1 mm, with at least a portion of the fibers being coated with the thermoplastic material. The fibers collectively define a network structure in which the fibers are interconnected with each other and fixed relative to each other via the thermoplastic material so that the coated fibers define interstitial voids therebetween. The article further includes first and second skin layers, the first skin layer having a surface integrally connected to the first surface of the expanded core layer and the second skin layer having a surface integrally connected to the second surface of the expanded core layer.

Abstract: A process for preparing an expanded product of a thermoplastic resin which includes a gas dissolving step of adding supercritical carbon dioxide and/or nitrogen as an blowing agent to a thermoplastic resin, and melting it in the thermoplastic resin, a cooling step of cooling the resulting molten resin composition under a pressure not less than a critical pressure of the blowing agent, a nuclei forming step of discharging the molten resin composition from a die to lower the pressure to a level not more than the critical pressure, and an expansion controlling step of cooling an expanded product of the thermoplastic resin to a level not more than a glass transition temperature or a crystallization temperature of the resin to control a cell diameter of the expanded product.

Abstract: Improved compositions useful for the production of foamed rotomolded articles are provided. The compositions of the invention are comprised of a first thermoplastic resin component which is an ethylene polymer in pellet form containing a foaming agent and a second thermoplastic resin component which is a powder consisting of a mixture of different particle size and melt index ethylene polymers. An improved process for producing foamed rotomolded articles having uniformly foamed interiors and smooth exterior skins which are substantially free of surface defects is also provided.

Abstract: Compositions, methods, and systems for manufacturing articles, particularly containers and packaging materials, having a highly inorganically filled matrix. Suitable inorganically filled mixtures are prepared by mixing together an organic polymer binder, water, one or more aggregate materials, fibers, and optional admixtures in the correct proportions in order to form an article which has the desired performance criteria. The inorganically filled mixtures are molded to fashion a portion of the mixture into a form stable shape for the desired article. Once the article has obtained form stability, the article is removed from the mold and allowed to harden to gain strength. The articles may have properties substantially similar to articles presently made from traditional materials like paper, paperboard, polystyrene, plastic, or metal. They have especial utility in the mass production of containers, particularly food and beverage containers.

Abstract: The invention relates to an improved sound absorbing cementitious composition and method of making involving a preformed foam solution made from a surfactant, such as an ammonium salt of a sulfated linear alcohol ethoxylate surfactant, preblended with water at a dilution ratio in a range of water to surfactant of from about 40:1 to 10:1. Thereafter, the preformed foam solution is combined with components including cement(s), aggregate(s), water and optional additives. The composition provides for an open cellular surface capable of absorbing sound.

Abstract: A composition containing thermoplastic elastomer and elastic fine particles is extruded into a sheet-like shape from an extruder. Then, by expanding this sheet-like shape member, a covering sheet having minute unevenness attributable to the elastic fine particles formed on the surface is produced. The covering sheet may have an adhesive layer, a substrate layer, a foamed resin layer, etc., on the opposite side to the surface having a matt feeling. Such covering sheet can be produced with good productivity without creating environmental problems such as a problem related to solvent, etc. By molding using the covering sheet, a molding having matt feeling can be obtained.

Abstract: A method for continuously producing an insulation board comprising a rigid plastic foam core having two major surfaces and a facing material on one or both of the major surfaces, the method including conveying a facing material along a production line, depositing a partially expanded froth foam of a plastic mixture, which contains at least one frothing agent, on the facing material, and further expanding and curing the froth foam in contact wiht the facing material to form the insulation board. The board is particularly useful as roof insulation.