Abstract: A molding press for simultaneously molding a product and laminating a pattern layer to the surface of the molded product comprising a bottom mold plate, a top mold plate, a mold ring element surrounding the mold plates and moveable independently of the top and bottom mold plates, an upper surface on said mold ring for engaging a peripheral edge of the top mold plate, and a flat groove in said mold ring upper surface which is slightly deeper than the thickness of a pattern layer to be laminated to the top surface of the final molded product.

Abstract: A process for producing a foamed article of a thermoplastic resin composition having a relatively thicker solid skin layer exhibiting better appearance without occurrence of 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 the stiffness, in an easy and efficient manner, by causing the said resin composition to foam up in a cavity of a mold, which process comprises

Abstract: A foamed thermoplastic resin fiber reinforced part is provided. The part comprises a member formed of thermoplastic resin, a plurality of cells and a plurality of reinforcing fibers dispersed within the member, and a skin formed on at least one exterior surface of the member. The skin is substantially devoid of cells. Here, the reinforcing fibers have a length of about 25 mm in an amount of about 10% by weight of the foamed thermoplastic resin fiber reinforced part. At least one of a cell density and a cell size of the plurality of cells is inversely proportional to the amount of the reinforcing fibers dispersed within the member.

Abstract: A composite sheet having a first, foamed polycarbonate resin layer and a second, non-foamed polycarbonate resin layer provided on at least one surface of the first layer and having a melt tension of at least 2.45 cN at 250° C.

Abstract: A fabric-less part and a method of making same are disclosed. The fabric-less part may include a flexible polyurethane foam body, a high-density polyurethane foam backing layer bonded to the foam body, and a polyurethane elastomer skin bonded to the backing layer. Alternatively, the backing layer may be eliminated and the polyurethane elastomer skin is directly bonded to the flexible polyurethane foam body. The fabric-less part may be an automotive interior part such as a pillar trim, headrest, trim panel, instrument panel, door panel, armrest, or part of an automotive seat such as a seat cushion.

Abstract: The foamed laminate based on olefin according to the present invention is composed of a substrate layer of a foamed body made of either an ethylenic thermoplastic elastomer comprising a polyethylene resin and an ethylene/&agr;-olefin copolymer having a Mooney viscosity ML1+4 (100° C.) of 90-250 and an ethylene content of 70-95 mole % or an ethylenic thermoplastic elastomer composition comprising 100 parts by weight of an olefinic thermoplastic elastomer and 1-20 parts by weight of an olefinic thermoplastic resin and, under lamination thereon, a skin layer made of either an ultrahigh molecular weight polyolefin resin having an intrinsic viscosity of 3.5-8.3 dl/g or made of an olefinic thermoplastic elastomer composition comprising an olefinic thermoplastic elastomer and a lubricant.

Abstract: A semiconductor cleaning device having a substantially cylindrical roller body made of polyvinyl acetal with a smooth outer surface and uniform material porosity having a mean flow pore pressure ranging from about 0.30 PSI to about 0.35 PSI with 95% of its pores ranging from 7 to 40 microns in size and a wet flow rate ranging from about 80.0 L/min to about 7.0 L/min.

Abstract: A cellular molded article in a mold pattern having the surface skin, which has an excellent releasing property from a metal mold as well as an excellent printing property of a design formed on a surface of metal mold, and a producing method thereof are provided.

Abstract: The method of forming a light-weight, fiber-reinforced, particularly glass fiber-reinforced-thermoplastic resin product includes the steps of melting and mixing thermoplastic resin pellets containing parallely oriented fibers 2-100 mm long, injecting the melted resin into a cavity which is closed so that its volume is smaller than that of the final molded product, and, before or after the resin injection is completed, opening the cavity until its volume is equal to that of the final molded product. Unlike the conventional injection-molded products, this product does not require a foaming agent and, if it uses any, requires only a small amount of foaming agent. The product thus formed is light in weight and has fibers uniformly entangled inside, providing an excellent appearance of the surface. Further a skin layer is formed over the surface. These features combined with the reinforcement by the glass fibers offer high strength and high stiffness.

Abstract: A reaction-injected foam molding comprising a skin coating film formed by the in-mold coating method and having an elongation at break of 20-200% (JIS K 6400: No. 1 dumb-bell test specimen) and a urethane foam body obtained by reaction injection molding and having a density of 0.35-0.60 g/cm3. Said molding permits easy removal of flashes even though the urethane foam body is of a high ratio expansion with a density of 0.35-0.60 g/cm3.

Abstract: A fabric-less part and a method of making same are disclosed. The fabric-less part may include a flexible polyurethane foam body, a high-density polyurethane foam backing layer bonded to the foam body, and a polyurethane elastomer skin bonded to the backing layer. Alternatively, the backing layer may be eliminated and the polyurethane elastomer skin is directly bonded to the flexible polyurethane foam body. The fabric-less part may be an automotive interior part such as a pillar trim, headrest, trim panel, instrument panel, door panel, armrest, or part of an automotive seat such as a seat cushion.

Abstract: A polyvinyl acetal sponge sheet of a porous structure having fine continuous pores and a film on the surface thereof. This sponge sheet can be used for a wiping material for car washing which does not leave unwiped portions during wiping after car washing and has a small frictional resistance and a high working factor.

Abstract: The method of forming a light-weight, fiber-reinforced, particularly glass fiber-reinforced-thermoplastic resin product includes the steps of melting and mixing thermoplastic resin pellets containing parallely oriented fibers 2-100 mm long, injecting the melted resin into a cavity which is closed so that its volume is smaller than that of the final molded product, and, before or after the resin injection is completed, opening the cavity until its volume is equal to that of the final molded product. Unlike the conventional injection-molded products, this product does not require a foaming agent and, if it uses any, requires only a small amount of foaming agent. The product thus formed is light in weight and has fibers uniformly entangled inside, providing an excellent appearance of the surface. Further a skin layer is formed over the surface. These features combined with the reinforcement by the glass fibers offer high strength and high stiffness.

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

Abstract: A thermoplastic elastomer composition powder obtained by blending 0.1 to 5 parts by weight of (c) described below per 100 part by weight of a pulverized product of a thermoplastic elastomer composition comprising 10 to 250 parts by weight of (b) described below or 10 to 250 parts by weight of (b) and 0.01 to 10 parts by weight of (d) described below per 100 parts by weight of (a) described below, and having a complex dynamic viscosity &eegr;* (1) of 1.5×105 poise or less and a Newtonian viscosity index n of 0.67 or less, and a powder molding process and molded article using said powder, (a): a polyolefin-based resin, (b): a rubbery polymer imparting a new single tan &dgr; peak at a temperature different from that of the tan &dgr; peak of (a) and that of the tan &dgr; peak of (b) within the range of −70 to 30° C.

Abstract: The present invention provides a lightweight fiber-reinforced thermoplastic molding containing reinforcing fibers whose average fiber length is maintained at 1 mm or more and having, as a sectional structure in its thickness direction, a skin layer having almost no voids, a foamed or expanded layer with a percentage of void of 10-50 vol % and a beam-supported structure layer with a percentage of void higher than that of the foamed or expanded layer in which the reinforcing fibers are intertwined complicatedly with each other and the fibers are fixed to each other with the thermoplastic resin in the vicinity of their contacts, said lightweight fiber-reinforced thermoplastic molding having a high percentage of void and is lightweight and excellent in bending rigidity.

Abstract: Foamed polymer-fiber composites, building materials and methods of making such building materials are provided by this invention. The composites include about 35-75 wt. % of a polymeric resin, about 25-65 wt. % fiber and have a specific gravity of less than about 1.25 g/cc. The low density is provided by the introduction of a blowing agent or gas into a molten precursor of the composite during thermo forming, such as in an extrusion operation.

Abstract: There is a need for polymers that offer a high level of heat and ultraviolet light resistance. It is particularly critical for polymers that are utilized in making skin compounds for automotive instrument and door panels to display excellent heat and ultraviolet light resistance. Polymer blends having such characteristics can be made by blending certain rubbery polymers with halogen containing polymers, such as polyvinyl chloride (PVC). There is currently a demand for halogen-free polymers having such characteristics. This invention discloses a rubbery polymer that can be blended with polyolefins, such as polyethylene or polypropylene, to make leathery compositions having good heat and ultraviolet light resistance. The rubbery polymer of this invention is comprised of repeat units which are comprised of (a) butyl acrylate, (b) an alkoxyalkylene acrylate, (c) styrene, (d) a half ester maleate soap, and (e) a crosslinking agent.

Abstract: A motor vehicle has a first body part with a seal support flange thereon that supports a unitary seal construction having a flexible bulb seal portion engageable with second vehicle body part including a hood or other vehicle body part for sealing against leakage between the first and second vehicle body parts and an integrally formed base portion and wherein the flexible bulb seal is hollow and is formed of a soft low density thermoplastic foam and the integrally formed base portion is integrally extruded with the flexible bulb seal and is formed solely from polymeric material having spaced walls defining a recess for fitting the unitary seal construction in place on the support flange.

Abstract: The present invention provides microcellular articles, as well as methods and apparatuses for producing polymeric foams, and, in particular microcellular material. The methods involve forming a gas blanket within a polymer processing die that prevents contact between the polymer melt and surfaces of the die during extrusion. In one set of embodiments, the gas blanket is provided by gas diffusing out of surfaces of the nucleated polymer material. In other embodiments, the gas blanket is formed by introducing a gas from an external source into the polymer flow channel within the die. The dies, according to the invention, are specially configured to generate and to support the gas blanket. The extruded foams are free of surface defects that, typically, arise from contact between the polymer melt and the die surfaces.

Abstract: A multilayer molded article is produced using a composite skin layer made of a skin material and a foam sheet on a core layer of a thermoplastic resin in which a tensile modulus E of the skin material is not larger than 950 kg/cm2, and a tensile modulus E (kg/cm2), a heat shrinkage factor F (%) and a thickness t (cm) of the skin material satisfy the following relationship: 20/(E×t)+F≧2.5, which method produces a large size multilayer molded article having a complicated shape and no wrinkles, breakage or uneven marks in the skin material on the surface of the article.

Abstract: The present invention provides a foamed thermoplastic resin article having light weight and high stiffness suitable for interior members for automobile, as well as having soft feel of a skin layer, which is formed by integrally laminating a skin material and a thermoplastic resin foamed base material while forming the same, wherein the thermoplastic resin foamed base material is composed of a foamed core layer, a skin layer of the skin material side and a skin layer of the backside, and when thickness of the skin layer of the skin material side is defined as A, and thickness of the skin layer of the backside is defined as B, the A and B satisfy the relationship of A<B.

Abstract: A porous cellulose sheet which has a structure less likely to develop curl and twist, and which can be continuously and stably manufactured, and a method for manufacturing such a sheet. The sheet has pores inside and formed with skin layers on both sides. The difference in thickness between the skin layers is not more than 50%.

Abstract: The invention is directed to an oriented multi-layer film which comprises a voided layer and at least one non-voided layer on at least one surface of the voided layer. In one embodiment, the voided layer comprises a Ziegler-Natta or metallocene-catalyzed substantially isotactic propylene polymer in a polymer matrix with a cavitation initiator. In a second embodiment, the non-voided layer comprises a Ziegler-Natta or metallocene-catalyzed substantially isotactic polypropylene polymer. In a third embodiment, both the voided core layer and at least one non-voided layer comprise a metallocene-catalyzed substantially isotactic polypropylene polymer.

Abstract: Fiber-reinforced vehicle interior trim and a method of manufacturing interior trim in a one-step molding process. A skin material and fibrous reinforcement mat are located in a molding tool. A moldable foam-forming material is applied to the tool between the skin material and the fibrous reinforcement mat. The foam-forming material penetrates the mat and expands and cures such that the foam binds to both the skin and the reinforcement mat to produce a molded interior trim piece.

Abstract: A process for the injection molding of a foamable plastic composition which comprises the steps of injecting a molten foamable plastic composition into a cavity having a lower volume than that of a desired molded article; after the completion of injection filling, cooling the composition to the state wherein a solidified layer in contact with a mold surface mingles with a molten inside layer; enlarging the volume of the cavity to that of the desired molded article; and after further cooling, removing the molded article. This molded article comprises a layer having a non- or low-foamed, dense structure on the surface and a high-foamed layer at the inside, and has a light weight and good thermal insulating properties.

Abstract: Disclosed is a protective foamed patch for a biaxially heat shrinkable, thermoplastic vacuum bag for protecting the bag from puncture by sharp protruding bones in the bone-in cuts of meat which are vacuum packaged within the bags. The patch is made from multi-layer film and comprises a layer of foamed polymer. The patch is biaxially heat shrinkable and shrinks with the bag. A method of making the patch is also disclosed.

Abstract: A method for forming an angled plastic article of varying density whereby a blowing agent is added to a plastic material and the material is injected into a mold cavity of a mold unit. The interior walls of the mold cavity are maintained at a temperature sufficient to prevent the outer skin of the hardening plastic article from producing gas bubbles. The volume of the mold cavity is increased to allow bubbles to produce and uniformly distribute themselves throughout the mold cavity and then a reconversion phase is instituted whereby the desired density of the finished plastic article is achieved without voids or aberrations appearing in the surface of the plastic article. The mold unit is provided with extensible beveled edges which extend and retract as the mold cavity is enlarged and compressed. By this method, a resulting plastic article of varying density is produced having grooves running the length of the article.

Abstract: An energy absorbing article having a direction in which impact resistance is desired is formed of extruded thermoplastic foam exhibit anisotropic compressive strength. The extrusion direction of the thermoplastic foam is aligned substantially parallel with the direction in which impact resistance is desired to provide an energy absorbing article exhibiting a high ratio of compressive strength to weight.

Abstract: An opaque, oriented polymeric film structure comprises: (a) a core layer containing a thermoplastic polymeric matrix material which has a first surface and a second surface, the core layer having a plurality of voids, substantially all or all of the voids being free from a void-initiating particle and at least some of the voids being interconnected with an adjacent void in the polymeric matrix material, the number of voids not containing a void-initiating particle being sufficient to impart a significant degree of opacity to the film structure; and (b) at least one outer or skin layer containing a thermoplastic polymeric material and an effective amount of a nucleating agent to suppress cavitation in said at least one outer or skin layer. The film structure has a smooth surface and can be tailored to provide a controlled permeability, and is particularly suitable for food packaging.

Abstract: A shock attenuation barrier including a plurality of layers successively arranged including a first layer, a second layer having a plurality of molded geometric shapes, a third layer including foam, a fourth layer having a plurality of molded geometric shapes and a fifth layer. Cavities defined by inside surfaces of the geometric shapes and a surface of the foam layer preferably are filled with a shock absorbing filler material.