Abstract: A bumper beam extension for a bumper beam having left and right bumper beam extensions and a method for manufacturing the bumper beam extensions to provide impact crush resistance is disclosed. The bumper beam extensions include an insert end contoured and sized to fit in the end of the bumper beam and a main body portion having substantially a rearwardly facing saddle shape that includes an upper wing and a lower wing joined at a bight section. The main body portion is blow molded to configure the bight section to taper from a preselected distance from a forward wall of the main body portion until it is face to face with the forward wall. For increased stiffness, the bumper beam may be welded to a frame of a vehicle.

Abstract: A method of manufacturing a plastic window for an automotive vehicle in which a hollow frame portion is separately molded from a main optical panel the frame portion bonded to the perimeter of the main panel as by melt bonding.

Abstract: A method for producing an endless belt for electrophotography by melt-extruding a thermoplastic resin having a diphenyl sulfone structure represented by the following Formula (1) from a circular die to produce the endless belt continuously 1

Abstract: A new die insert for an extrusion machine and a method of using the invention that includes a continuous strand of fiber reinforcing material to be statically drawn directly to the center of the molten flow of polymer base matrix is provided. The insert is placed in line with the discharge end of an injection molding apparatus. A molten flow of polymer base matrix proceeds in a straight linear fashion through the die. A fiber feed tube is centered on the interior of the die. As the polymer flows past the feed tube the molten polymer draws a continuous strand of fiber reinforcing into the center of the flow. The polymer is then extruded and cooled and the extrusion is further pelletized to produce injection molding feed stock material having continuous fiber reinforcing. The result provides a continuous extrusion process that allows the formation of a continuous fiber-reinforced product employing brittle fibers in one-step process.

Abstract: Window components are made by a fluid-assist injection molding process to reduce manufacturing costs and provide additional flexibility in the configuration of the window. In addition to the inventive product-by-process, two window configurations, a casement window and a picture window, are taught. The casement window has a frame with installation flanges and the window sash has integral mounting posts for handle hardware. Both the window frame and sash have encapsulated insulative air pockets. An acrylic window pane is taught that mimics a glass block window.

Abstract: A system and process for gas-assisted injection molding of plastic materials using gas holding pressure in the mold cavity. An infinitely controlled gas pressure valve is utilized to provide initial pressure in a sealed mold and the gas is vented to a prespecified pressure when plastic is injected into the mold cavity. Additional gas is injected into the plastic material from a gas pin assembly in order to force the plastic to completely fill the mold cavity and to provide a hollow cavity in the completed part. Once the injection molding process has been completed and the part has cooled and solidified, the mold is opened, and the completed plastic molded component or part is removed or ejected.

Abstract: An apparatus, mounted to a mold, for injecting air into a mold cavity and removing exhaust from the mold cavity, comprising: a blow cylinder body block mounted to the mold having a conduit to the mold cavity, wherein the blow cylinder body block comprises an insulator and the conduit has walls; a needle passing through the blow cylinder body block and the conduit, wherein the needle is connected to a piston, wherein the needle has a needle passage, and wherein compressed air is applied to the piston to extend the needle into the mold cavity and retract the needle from the mold cavity; and an insulator between the needle and the conduit walls.

Abstract: A process for producing an injection molded article with a hollow rim portion in an injection molding machine including the steps of injecting a short shot of injection molding material into a mold via an injection nozzle, permitting a mold cavity to fill in an unbalanced manner as a result of a gas channel formed in a wall of the mold, closing the injection nozzle; and injecting a pressurized gas into the short shot of injection molding material, wherein the pressurized gas travels through the gas channel into a rim portion of the mold thereby expanding the injection molding material throughout the mold and simultaneously creating a hollow cavity within the rim portion of the mold.

Abstract: A method and system for producing hollow rib structures for trim components and panels using gas assisted injection molding. Rotatable insert members with recesses therein are provided in the mold cavity, particularly at the ends of the structural rib members. Once the plastic material has been injected into the mold cavity, the insert members are rotated, exposing said recesses to the mold cavity. Then, gas is introduced into the rib members displacing a portion of the molten plastic material into the recesses forming hollow channels or openings in the plastic material. The displaced resin material completes the formation of the molded plastic article.

Abstract: A window for automobiles or the like, including a frame member which is composed of a thermoplastic synthetic resin material and formed integrally with a window plate. The frame member includes a substantially U-shaped cross-sectional portion formed of lip and web sections which are spaced from and opposed to each other on outer and rear surfaces of the window plate, respectively, and connected with each other by a bridge section having a continuous hollow inner space therein. The frame member is formed by injecting into a mold cavity a relatively small amount, as compared with the volume of the mold cavity, of molten thermoplastic synthetic resin material, and by injecting compressed gas into the resin material to urge the resin material against inner surfaces of the mold defining the cavity.

Abstract: A process for manufacturing hollow handled toothbrushes is disclosed. The process includes; a) providing a toothbrush mold having a head portion, a base portion, a toothbrush cavity located between said head and end portions and having walls, an injection port for molten plastic, and a gas injection port, wherein the gas injection port is positioned in the end of the base portion of the mold so that gas is injected into the mold cavity substantially centrally thereof and in a direction parallel to the longitudinal axis of the mold; b) injecting a predetermined amount of a molten plastic into the mold cavity to partially fill the cavity; and c) injecting at least one gas through the gas injection port into the cavity to direct the molten plastic against the walls of the mold cavity.

Abstract: A self cleaning pin for a fluid assisted injection molding apparatus that includes a pin body with a fluid passage and a shaft member. The shaft member is positioned in the pin, and is reciprocable between a retracted position and an extended position, wherein reciprocation of the pin drives intruding plastic from the end of the pin body. In its retracted position, a tip portion rests against a substantially mating seat, and provides continuous fluid communication between the fluid passage and a mold cavity. The pin also provides adjustable biasing means, the biasing means continuously biasing the pin toward its retracted position. A shaped recess is included in the end of the shaft member, and can be utilized to manually rotate the pin relative to a tensioning member threadedly received on the shaft member, thereby adjusting the biasing force.

Abstract: Improved method for gas assigned injection molding of automotive moldings and trim parts is disclosed wherein a pressure drop cavity is provided in the mold cavity structure adjacent to the gas channel. Admission of the gas into the gas channel during the molding process creates gas flow into the pressure drop cavity and into the major cavity that forms the general shape and configuration of the part.

Abstract: The present invention provides a process for fluid assisted injection molding comprising the step of providing an injection molding apparatus having a mold body that defines a mold cavity. The process further comprises the steps of supplying a quantity of fluent plastic to the mold cavity, followed by injecting a fluid into the mold cavity. The fluid forms an expanding fluid pocket in the mold cavity, driving plastic to the furthest recesses of the mold and ensuring a smooth surface finish of the final molded product. A reservoir is selectively connectable to a plastic injection runner, and can be opened to the runner to receive molten plastic ejected by the introduction of the fluid to the mold cavity. When the reservoir is thusly connected, the pressure of the fluid forces the plastic through a supply passage, in a direction substantially opposite to its initial injection direction.

Abstract: A method for molding through parts employs gas-assist molding techniques. The method includes closing a mold to create a part cavity, injecting resin into the mold, injecting a gas into a resin stream to create hollow sections in the part, opening the mold, and ejecting a part using conventional mold ejection techniques. The final step of the process includes trimming the as-molded part to expose the through section of the fitting. The fitting may be molded with sealing features for use in tubing assemblies. Advantages of this process include higher working pressure ranges, as well as reduced manufacturing costs and assembly time. The molded tubing fitting formed in this process invention is a through fitting which incorporates features representing o-rings installed on a part into the mold and ultimately into the exterior surface of the molded fitting. This process may eliminate injection molded o-ring fittings from the connection entirely.

Abstract: The invention relates to a method and an apparatus for injection molding thermoplastic molded parts, having at least one cavity. The method comprises the following steps: a) injecting thermoplastic melt from an injection unit along a melt flow path into the cavity of an injection molding tool; b) injecting a fluid into the still liquid plastic material, so that the plastic material is pressed against the walls of the cavity; c) allowing the plastic material to cool until it forms the self-supporting molded part; and d) removing the molded part from the cavity of the injection molding tool.

Abstract: A process for injection molding of molded parts made from thermoplastic plastic material having at least one cavity, which includes: a) injection of thermoplastic plastic melt from an injection unit along a melt flow path into the cavity of an injection-molding die; b) injection of a fluid into the still molten plastic material, so that the latter is pressed against the walls of the cavity; c) allowing the plastic material to cool until the latter forms the molded part in self-supporting manner; and d) releasing the molded part from the cavity of the injection-molding die.

Abstract: An ejector pin of an injection mold includes a sleeve, a valve structure, and a biasing member. The sleeve has a passage hole and an enlarged hollow portion, which communicate with each other via a stepped portion engaged therebetween. The valve structure has a valve portion and a collar portion, which are disposed in the sleeve. The collar portion of the valve structure is biased by the biasing member such as a spring and stopped by the stepped portion. Gaps interposed between the valve structure and the sleeve serve as a gas passageway through which gas in a molding cavity is exhausted by a vacuum pump.

Abstract: A method for manufacturing a molded article comprises injecting a quantity of molding material sufficient for the preparation of the molded article into a cavity of a mold, injecting a first portion of fluid into the mold cavity, creating a gas channel within the molding material, and forming the molded article within the mold cavity. At least a portion of the first portion of fluid is exhausted through a gas port, a second portion of fluid is injected into the mold material, and the molded article is cooled within the mold cavity to a temperature beneath a softening point of the molding material.

Abstract: An assembled plastic door made of door skins and formed from a molten plastic resin by gas assisted thermoplastic injection molding.

Abstract: The present invention provides an injection molding method for providing a molded product with excellent transcription and an excellent gloss level. In this method, immediately after a resin is filled in a cavity (1), a carbon dioxide gas is injected or the skin layer is moved back to form a space (13) between the resin and the die surface (1), so that growth of the skin layer is hold down, and at the same time the carbon dioxide is dissolved in the skin layer for lowering the glass transition point of skin layer. Then the skin layer is again closely cohered to a surface of the die by increasing the resin pressure and cooling the molded product for solidifying behind the holding pressure. With this method, products with excellent transcription and with an excellent surface gloss level can be obtained.

Abstract: A liquid and gas assisted injection molding apparatus comprising a source of liquid coolant, a source of compressed gas, a source of heated viscous plastic, a mold cavity means for controllably injecting said plastic into said cavity, means for controlling injecting said compressed gas into said cavity, means for controllably injecting said liquid coolant into said cavity, and means for selectively controlling the injection of said plastic, gas and liquid coolant.

Abstract: A nozzle assembly for gas-assisted injection molding having a nozzle body, a shutoff pin, a helical spring, a spring guide and a gas-injection valve assembly. The nozzle assembly is a simple design including minimal components, thereby resulting in ease of maintenance and reduced cost. The nozzle assembly is self-actuating, using direct resin pressure to open the nozzle assembly, thereby enabling the flow of molten resin through the nozzle and into a mold cavity. After injection of the molten resin, the helical spring automatically engages the shutoff pin thereby closing the nozzle assembly to prevent backflow. The gas-injection valve assembly is similarly self-actuating such that minimal operator supervision is required to operate the nozzle assembly.

Abstract: The present invention relates to the fabrication of a moulded detail in a gas assisted moulding process, wherein molten polymer (23) is injected into the mould cavity (21) of a moulding tool, pressurized fluid (25) is supplied to the mould cavity through at least a first opening (22) to form a cavity (26) in the polymer and force the polymer towards the inner walls of the mould cavity, pressurized fluid (27) is thereafter supplied to the mould cavity through at least a second opening (24) localized remotely front said first opening to form a passage (28) through the polymer to said cavity, the polymer is cooled, pressurized fluid is removed and the mould cavity is opened to remove the moulded detail.

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: The present invention provides processes and an apparatus for injection-molding an article with a fluid channel formed therein. The process includes providing at least first and second resin streams within a mold cavity, causing the flow fronts (16) of the resin streams to meet at a longitudinal point in the mold cavity to form a first layer of solidified resin on a peripheral surface of the mold, the first layer having a knit line (20) at the longitudinal point where the resin streams meet; and introducing a fluid into the molten resin in the mold to form a fluid channel (50) and a second layer (32) of solidified resin, the second layer between the fluid channel and the first layer of solidified resin, wherein the second layer is devoid of a knit line at the longitudinal point in the mold cavity where the first and second flow fronts meet.

Abstract: A method is provided for gas-assisted injection molding for forming a hollow product. The mold cavity is prepressurized with fluid prior to injecting the molten material into the mold cavity, and the molten material is injected into the mold cavity against the pressurized fluid to establish a resultant internal counterpressure within the molten material. A pressurized assist-gas is injected into the molten material to form a gas bubble within the molten material. The injection of molten material into the cavity is then controlled in a manner to maintain the internal counterpressure at desired levels to overcome stress forces and to control formation and movement of the bubble within the melt.

Abstract: An apparatus and a method are disclosed for manufacturing an integral one piece catheter having a tube and a hub. The method comprises feeding molten material into a mold having a mold cavity. A fluid such as a gas is injected into an inlet of the mold. This causes the cavity to eject the molten central region of the polymer through an exit channel. In one embodiment, a gas is injected into the hub portion of the cavity. In another embodiment, a gas is injected into the catheter portion of the mold. The invention also involves forming a first portion of an intravascular device using a first material in a first mold. Thereafter the first portion of the intravascular device is inserted into a second mold to form a second portion using a second material. Gas is then introduced to form a hollow channel in the second portion.

Abstract: A method and apparatus for shape forming of degradable polymers under the protection of an inactive gas is disclosed to use an injection-molding machine to mold a degradable polymer into final products, and to use an inactive gas to form an air shield that isolates the supplied degradable polymer from air during injection molding.

Abstract: A process for injection molding a composite of rigid thermoplastic and soft thermoplastic, the soft thermoplastic including a cavity established with pressurized assist gas or an assist liquid. The process includes the steps of: injecting a hard molten thermoplastic into a first mold chamber; injecting a soft molten thermoplastic into a second mold chamber; establishing communication between the first chamber and the second chamber so that the rigid thermoplastic and soft thermoplastic integrally bond; and injecting an assist fluid into the soft thermoplastic to form a cavity. In a preferred embodiment, the formed composite is an automotive cowl where the rigid thermoplastic forms the rigid body portion of the cowl and the integrally bonded soft thermoplastic forms a compressible bulb seal.

Abstract: According to the inventive method for shaping hollow bodies made of thermoplastic material which comprise at least one gas pocket (3) having a wall (6), said wall (6) of the gas pocket(s) (3) is externally subjected to the action of pressure in all-over manner, and the hollow body to be shaped is heated when the wall (6) of the gas pocket(s) (3) is being externally subjected to the action of pressure. A device is Configured for carrying out the inventive method. The inventive method or device prevent an undesired deformation or a bursting open of the wall of the gas pocket(s) when heating the hollow body.

Abstract: In a process and apparatus for producing hollow bodies from plastic material which are at least partially filled with foam, firstly a preform is expanded in a blow molding mold by an increased internal pressure to form a hollow body which is then at least partially filled with foam plastic beads. The compressed beads are introduced into the expanded hollow body while still within the mold, under a pressure which is higher than the pressure obtaining in the hollow body. The beads in the hollow body experience a relief of pressure which results in the increase in volume of the beads and which provides for at least very substantial filling with a foam of at least a delimited part of the volume in the hollow body.

Abstract: A method for continuously forming discrete hollow parts includes extruding at least one continuous stream of molten plastic. A plurality of mold segments are arranged such that one or more segments periodically close on the one or more streams of molten plastic and define discrete part forming cavities when closed. A pressure differential is created within the discrete part forming cavities to shape the molten plastic accordingly. Air or another gas is replenished within the discrete hollow parts either in the discrete part forming cavities, or nearly immediately upon discharge from the cavities. The discrete hollow parts are then cooled. The apparatus for forming discrete hollow parts in this manner has an extruder and a plurality of the mold segments including one or more segments that can be closed on the plastic stream or streams. The pressure differential is applied by the apparatus to the closed mold segments. The hollow part interior is replenished either by the apparatus or manually by an operator.

Abstract: A cooling procedure for the manufacture of plastic parts by injection, that uses a gas under pressure that is lodged in the cavity provided by the two mould parts (1, 2) during at least the cooling phase. The cold gas, and its application, covers both coated and non-coated part.

Abstract: A method for the compression molding of a plastic article is provided. The method includes the steps of loading plastic material, that is preferably unheated, into a two piece molding chamber having at least one heating element, closing the molding chamber, and heating the plastic element. The method further includes the step of injecting fluid, for example air, into the plastic material to create at least one cavity within the plastic material. The air may be injected directly into the plastic material, or it may be injected along an upper surface of the chamber. Upon injection of air into the at least one cavity, a portion of the plastic material is forced to exit the chamber.

Abstract: A method and apparatus for forming a green ceramic arc tube for a metal halide lamp. A feedstock material comprising ceramic and a binder is prepared and injected into an inner cavity of a mold. The inner cavity of the mold has an inner surface that corresponds to a desired outer shape of a body of the ceramic arc tube. A fluid is injected into the feedstock material to create a cavity in the feedstock material and to force the feedstock material into contact with the inner surface of the mold. The mold is then separated from the formed ceramic green arc tube.

Abstract: A wiper brush arm for a motor vehicle includes a rigid molded plastic single-piece body having a generally elongated shape whereof one end is driven in reciprocating wiping movement, and the other end bears a wiper brush or a wiper blade. The body is coated at least partly with a protective layer protecting the body against external environmental attacks, such as ultraviolet radiation. The protective layer is made of plastic material.

Abstract: The present invention provides a composition of reinforced polyamide (PA) for use in a cooling circuit of an engine. The composition may be processed by a gas injection technique (GIT) into shaped parts having smooth inner surfaces and a good hydrolytic stability against cooling medium such as glycol/water mixtures.

Abstract: A liquid and gas assisted injection molding apparatus comprising a source of liquid coolant, a source of compressed gas, a source of heated viscous plastic, a mold cavity means for controllably injecting said plastic into said cavity, means for controllably injecting said compressed gas into said cavity, means for controllably injecting said liquid coolant into said cavity, and means for selectively controlling the injection of said plastic, gas and liquid coolant.

Abstract: Thermosetting polymer is introduced into a mold at one end thereof to fill said mold. After a predetermined length of time to permit the thermosetting polymer to polymerize along the wall of the mold to form a wall of the desired thickness, gas is introduced into said mold at the opposite end to eject the central unpolymerized portion of the thermosetting polymer from the mold, leaving behind in the mold a hollow formed article.

Abstract: An apparatus for producing a plastic molded article or product for use in an optical device is a mold assembly. The mold assembly includes a pair of molds having an inner mold surface forming a cavity with a preselected volume into which a molten molding material is injected via a gate or sprue to fill the cavity and thereby form a molded product having a sink surface and at least one mirror surface after the molten molding material has cooled. The inner mold surface includes at least one transfer surface portion against which the at least one mirror surface of the molded product is formed, and at least one non-transfer surface portion against which the sink surface portion of the molded product is formed. The mold assembly also includes at least one vent hole, at least one bore in communication with the vent hole so that a preselected air pressure is applied to the molten molding material in the cavity via the bore and the vent hole, and at least one exhaust hole adjacent to, but spaced from the vent hole.

Abstract: The invention provides a method and apparatus for injection moulding a plastics article having thin and thick wall sections (14; 15). A quantity of molten plastics material (19) is introduced sufficient to fill the mould cavity, followed by a further quantity of molten plastics material sufficient to pack at least the portion or portions of the mould cavity in which the thin wall section or sections (14) are formed. Pressurized fluid is introduced through the or each fluid injection member to penetrate the plastics material whereby a fluid-filled void (20) is formed within the plastics material adjacent to the inner end of the fluid injecting member, and fluid pressure is maintained within the or each void so that the void expands in response to the shrinkage of the immediately surrounding plastics material, during cooling, until the plastics material is self-supporting.

Abstract: A gas assisted molding apparatus having gas introduced into the plastic charge as the charge is flowing into the mold cavity. The gas and plastic are simultaneously injected into the mold cavity and the gas can be introduced at the nozzle end or barrel of the injection molding machine. Optionally, the gas may be injected into a hot runner manifold or into the cavity itself simultaneously with the plastic. The apparatus includes a conventional gas injection mold, a source of inert gas, such as nitrogen, and an injection assembly. A common power source is used for both the injection of the plastic and the gas to assure simultaneous inflow of both the gas and the molten plastic at the same pressure.

Abstract: A process for orienting and drawing multiple-layer thermoplastic materials, in particular of a tubular type, wherein a tube exiting from a heating tunnel is brought up to an orienting temperature of a first material having the highest orienting temperature, while the material of the remaining layers is still in a plastic state. The first material is subjected to a first partial drawing process, while the remaining layers plastically deform to follow its expansion. The temperature of the tube is dropped to the orienting temperature of a second layer and a second layer is drawn, while at the same time continuing to draw the previous layer. Steps of dropping the temperature and drawing the second layer are repeated for the subsequent layers, until the maximum allowable degree of drawing is achieved for each layer.

Abstract: A cement balance weight for a drum type washing machine and its manufacturing method. The balance weight includes a housing having a predetermined inner space and an opening for cement injection. The housing includes coupling features that assist coupling the balance weight with a tub.

Abstract: Manufacture of moulded polyurethane or moulded polyurethane containing products, especially thermoplastic products, such as elastomers, flexible foam, and rigid foam using gas assisted injection moulding. Preferred polyurethane products are thermoplastic polyurethanes.

Abstract: A system and process for gas assisted plastic injection molding, particularly of hollow tubular components. The plastic material is injected into the mold cavity through an apex of a cone-shaped inlet configuration. After the molding pressure is held for a period of time, gas is injected into the plastic material and pressure is again held for a period of time, a valve member is opened allowing plastic to be expelled into a secondary cavity. The flow of the plastic and gas are controlled in an axial direction in order to prevent turbulence. The gas flow axially along the center of the tubular member allows the expulsion of plastic from the center uniformly along the length of the tube. In an alternative process, the gas is displaced axially into the barrel of the injection molding machine.

Abstract: A system and process for gas assisted plastic injection molding. The plastic material is injected into the mold cavity and the molding pressure is held for a period of time. Thereafter, gas is injected into the plastic material and the pressure is again held for a period of time. Thereafter, valve members are opened allowing plastic to be expelled into one or more secondary cavities, or to be expelled back into the machine barrel.

Abstract: A mold for producing a hollow thermoplastic resin molded article includes a set of female and male mold members and a gas passage provided in at least one of the mold members which opens directly onto a surface of the mold member. Alternatively, a gas introducing member for introducing gas into a cavity may be provided in communication with the gas passage such that the tip of the gas introducing member does not protrude into the cavity of the mold. A lagging material, such as an insulating material or a local heater is preferably provided in the area of the mold adjacent the gas passage or gas introducing member. A method of producing a thermoplastic resin molded article using a mold of this nature is also disclosed.

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