Abstract: A mold for molding thermoplastic parts having a plurality of pinholes wherein at least one of the mold cavities has a number of projections in the form of three-dimensional tapering shapes, for example, cones, which extend to a point near to but spaced from the confronting surface of the other mold half cavity. The taper of the angle of the projection and spacing between the apices of the projection and the surface of the other mold half are selected so that molten thermoplastic freezes before it covers the apices of the projections during the molding process to thereby form pinholes in the resulting plastic part. A method for molding plastic parts with pinholes with the use of the mold cavity with multiple projections is also disclosed.

Abstract: A barrier wall (24) separating a passenger compartment from an engine compartment of a motor vehicle has an acoustical barrier assembly (102) mounted thereto. The acoustical barrier assembly (102) includes first and second mat portions (104, 106) juxtaposed to each other in overlapping relationship. Each mat portion (104, 106) is preferably of a molded construction and has sound dampening characteristics. The first and second mat portions (104, 106) each have a terminal edge (130, 122). The terminal edge (130) of the second mat portion is in engagement with one of the surfaces of the first mat portion to thereby acoustically seal the first and second mat portions together. Spacer ribs (124, 132) are integrally with the first and second mat portions (104, 106). Each ribs (124, 132) extends from its corresponding mat portion to the other mat portion.

Abstract: A barrier wall (20) separating a passenger compartment from an engine compartment of a motor vehicle has an acoustical barrier assembly (10) mounted thereto. The acoustical barrier assembly (10) includes a sound barrier layer (12) of a molded construction and sound dampening characteristics. At least one fastener (28) is integrally molded as a single piece with the sound barrier layer (12). The fastener (28) includes a plurality of outer spacer ribs (30) that project laterally from a tube (32) and space an inner surface (24) of the sound barrier layer (12) away from the barrier wall (20). A circumferentially extending flange head (34) is integral with the tube (32) and includes a first frusto-conical section (36) and a second inverse frusto-conical section (38).

Abstract: An acoustical barrier (10) is mounted to the barrier wall (20) of a motor vehicle. The acoustical barrier (10) includes a mass layer (12) of molded construction and sound dampening characteristics. The mass layer (12) includes a plurality of grommets (14, 14', 14", 54) integrally molded as a single piece with a lower surface of the mass layer. Each grommet (14, 14', 14", 54) has a continuous wall with an inner peripheral surface (27, 27', 27") with an upper portion of the wall integrally formed with the inner surface (18) of the mass layer and a lower portion of the wall having a lower edge (22, 22', 22") abutting the barrier wall (20). The inner surface (27, 27', 27") of the continuous wall defines an opening in each grommet (14, 14', 14", 54). A plurality of openings (25, 25', 25") in the mass layer are in communication with at least some of the grommet openings.

Abstract: A refuse container constructed of a rigid plastic material comprises a walled storage bin having substantially vertical walls extending upwardly from a bottom wall. The refuse container includes a wheel-bearing axle mounted to the lower rear portion of the storage bin and at least one wheel mounted to a front portion of the storage bin. To prevent downward deflection of the storage bin bottom wall, the refuse container also includes a brace disposed beneath the bottom wall which mounts to the rear axle and the front portion of the storage bin to reinforce the bottom wall.

Abstract: A reusable, releasably lockable wheel assembly comprising a wheel having a centrally disposed hub defining an aperture in which is received an axle. A spring having diametrically opposed lugs is disposed on one side of the hub and the lugs extend into the aperture of the hub so that when the axle is inserted into the aperture, the lugs are biased into the groove on the end of the axle to lock the wheel to the axle. The lugs can be forced outwardly by a tool to withdraw the lugs from the groove so that the axle can be unlocked with respect to the wheel for removal of the wheel. In one embodiment, cooperation between a wheel cover and the spring limits slidable movement between the wheel and axle. In another embodiment, cooperation between an end cap on the wheel hub and the spring limits the slidable movement.

Abstract: A process for producing a label bearing article (10) calls for an adhesive mounting of a label (16) to an exterior surface (14) of a thin thermoplastic substrate (12), and placing the thermoplastic substrate (12) and the affixed label (16) into a mold cavity of an injection molding apparatus with the label bearing exterior surface (14) against a wall of the mold cavity. A molten thermoplastic resin is injected into the mold cavity under pressure so that the resin contacts an interior surface (15) of the thermoplastic substrate (12) to thereby firmly press the exterior surface (14) of the thermoplastic substrate (12) and the affixed label (16) against the wall of the mold cavity, thereby forming the composite article (10). Sufficient heat and pressure are provided within the mold cavity to at least partially recess the label (16) into the exterior surface (14) of the thermoplastic substrate (12) and integrally mold the thermoplastic substrate (12) to the label (16).

Abstract: An integral fastener particularly for use in mounting a sheet material to a structural member with a plurality of threaded studs. The integral fastener in one embodiment is connected to the sheet by a web adjacent an aperture in the sheet. The fastener has an opening that defines multiple flaps. To fasten the sheet material to the stud, the stud is inserted through the sheet aperture and the fastener is pressed on the stud so that it extends through the fastener opening, deflecting the flaps, which engage the threads of the stud. In another embodiment, the fastener is formed within the sheet and defines an opening through which the stud passes. In a third embodiment, the stud comprises a T-shaped flange and the fastener has a slotted opening at an acute angle to the plane of the T-shaped flange to retain the fastener on the T-shaped flange.

Abstract: An acoustical barrier having a central aperture that is defined by a flexible seal. The acoustical barrier has an inwardly directed flange circumscribing of the central aperture and spacing the mass layer from a wall a predetermined distance. The wall has an aperture in which is disposed a moisture seal through which a pass-through component extending from one side of the wall to another side of the wall is positioned. The pass-through component is mounted to an article that is disposed within the central aperture of the acoustical barrier. The flexible seal is positioned away from the moisture seal and blocks the transfer of acoustical noise from one side of the wall to the other.

Abstract: A waste container having a container body to an upper portion of which is pivotally mounted a lid. A wheel and axle assembly is mounted to a lower portion of the container body to aid in the movement of the waste container. The waste container has an upper handle disposed near the upper portion of the container body and a lift handle disposed near the lower portion of the container body in opposing and vertically aligned relationship to the upper handle. The opposing relationship of the upper handle and the lift handle provides for a person to grasp the upper handle and the lift handle to lift and invert the waste container into a receiving vehicle to dump the contents of the waste container.

Abstract: An acoustic barrier for mounting to a barrier wall, such as a barrier wall between an engine compartment and a passenger compartment of a vehicle. The barrier wall has multiple indentations forming an uneven surface. The acoustic barrier comprises a decoupling layer and a mass layer. The mass layer has a series of projections formed on a rear surface, which coincide with the indentations of the barrier. When the decoupling layer is mounted to the rear wall of the mass layer, the projections alter the shape of the decoupling layer to conform with the shape of the barrier layer.

Abstract: A gas-assisted injection molding article suitable for plating and a method for plating the article is disclosed. A sleeve is selectively mounted on an upstanding gas injection stud formed on the molded article. The sleeve seals an aperture which extends through the sidewall of the gas injection stud to the hollow interior of the molded article. The sleeve is preferably formed of a heat shrinkable thermoplastic. After the sleeve has been mounted to the article, the sleeve is subjected to a source of heat such that it retracts and is securely mounted to the gas injection stud. With the aperture sealed, the article can now be submerged in a suitable plating bath or other liquid medium.

Abstract: A thermoplastic article can be injection molded in a mold (10) which includes a cavity (28) defining the shape of the article, at least one thermoplastic entry aperture (23) which is adapted to receive molten thermoplastic resin from a nozzle (22) of an injection molding machine (24), a thermoplastic flow path (21, 26, 30) communicating with the thermoplastic entry aperture and the cavity, and a fluid flow passageway (32, 34) extending into the mold. The fluid flow passageway extends from an exterior surface of the mold to the thermoplastic flow path. A low viscosity fluid such as a gas can be injected through the fluid flow passageway and into the thermoplastic flow path. An end portion (44) of the fluid is flow passageway adjacent the thermoplastic flow path has a porous me lug (50) disposed therein. The porous metal plug includes a porous metal core (64) which permits the low viscosity fluid to flow therethrough but prevents the passage of molten plastic therethrough.

Abstract: An acoustical barrier, an aperture and a pipe or cable passing therethrough wherein the aperture has a number of radially extending slits which define a plurality of radial sectors which also extend from the aperture. One or more grooves are arranged in the sectors concentrically about the aperture to increase the radial flexibility of the sectors so that the sectors more closely conform with the shape of the pipe or cable passing through the aperture and thereby reduce the spacing between the slits and reduce the noise passing through the seal.

Abstract: A process for injection molding a thermoplastic backing (12) or other synthetic resin to a carpet layer (14) by suspending the carpet layer (14) between two mold halves (46,48), injecting a thermoplastic resin into the mold, and injecting an inert fluid such as nitrogen into the mold at a relatively low pressure to assist in distribution of the thermoplastic resin throughout all points of the mold. The invention also relates to a synthetic resin backed carpet, which resin backed carpet may constitute a vehicle dashboard (10). The vehicle dashboard (10) can include an internal runner or rib (16) which has a hollow portion (52) formed substantially along its length, the hollow portion (52) being formed by injection of the inert fluid during the injection molding process.

Abstract: In a rotary fan (10) having a tubular drive shaft (14) and a lower cylindrical hub (16), an isolator bushing (20) interconnects the drive shaft (14) and hub (16) so as to substantially reduce vibrations. The bushing (20) is elastomeric, tapered and mounted within the hub (16) in an uncompressed state to maintain vibration-reducing properties. The drive shaft (14) extends into and terminates within a central bore (42) of the bushing (20), and the end portion of the shaft (14) is secured at a lower portion of the bushing (20). The hub (16) is secured to an upper end surface of the bushing (20) and the length of the bushing (20) provides dampening of vibrations caused by rotary motion. The tapering of the bushing (20), while maintained in an uncompressed state, provides dampening of vibrations caused by resonant frequency characteristics.