Abstract: A nylon cable tie having a head and a strap terminating in a tip is formed in a mold cavity defined between a first mold part combined wish a second mold part by injecting molten nylon material into the mold cavity through an insulated runner system and a gate that converges from the runner system toward the mold cavity and does not have a hot tip adjacent thereto. The mold parts are separated while retaining a portion of the head in a head region in the first mold part and a portion of the tip in a tip region in the second mold part, in order to separate the head from the second mold part, to separate the tip from the first mold part, and to separate a major portion of the strap from the first and second mold parts. The mold parts are further separated while retaining said portion of the head in the head region to thereby remove said portion of the tip from the second mold part. The head is ejected from the head region by protracted ejector pins that penetrate the head region from within the first mold part.

Abstract: A stopper for a rope which is injection molded on the rope. The stopper has a sleeve-like shape and surrounds the rope without play and prevents an axial slippage of the stopper from the rope. A strut is formed as one piece with the stopper and extends radially through the inner diameter of the rope. Also a method of forming a stopper on a rope is included.

Abstract: A molded article having an embedded bracket, such as a whirlpool tub, the mold and a method of molding the article. The article includes a rigid shell having a non-finish side and a finish side. The non-finish side is coated with a polymeric material. The polymeric material encloses a bracket and distributes the weight of an attached object, such as a whirlpool motor, over adjacent polymeric material. The bracket is affixed to the rigid shell in a spaced relationship and includes a surface for attaching to an object by attachment means such as a blind bolt. The bracket may also be affixed to the rigid shell by supports which are welded to the rigid shell.

Abstract: An electromechanical device for moving magnetic tapes or disks has a metal load-bearing plate provided with openings and injection molded plastic control rods and shafts held in phase by injection molded plastic retention pieces connected through the openings. These retention pieces are provided with a greater clearance relative to the metal load-bearing plate than that achieved by injection molding by a deformation blow to the plastic control rods and shafts after molding.

Abstract: A method of producing a decorative pattern on a plastic card housing an etronic circuit in an injection molding machine, includes the steps of introducing and positioning a film, which has applied on at least one surface thereof a decorative pattern, in an open cavity of the injection molding machine, closing the cavity so that the film is fixed and clamped in position, after the closing of the cavity, inserting an electronic circuit chip through an aperture into the mold cavity, injecting a support composition for the card into the mold cavity, and after termination of the injection process, removing the gate or any excess material from the periphery of the card, opening the mold cavity and removing the decorated card.

Abstract: A method of encapsulating a semiconductor device permits use of the same mold for various package types. In one form, a mold (34 and 36) has a first cavity (50) in which a first insert (52 and 53) is positioned, the first insert defining a length and a width of a package body which is to be formed in the mold. The first insert in the first cavity also defines a second cavity (54) in which a second insert (56 and 57) is positioned, the second insert defining a thickness of the package body. Plastic is inserted into the mold to form the package body. To form other package types, one or more inserts are replaced instead of using a different mold. In another embodiment, the inserts are adjustable. For example, rather than having to change inserts to form a package with a different thickness, the inserts are adjusted by, for instance, a screw mechanism (66) within the mold or by the addition or removal of shims (60).

Abstract: A process of forming an article wherein a resinous material is heated to a first temperature sufficient to release substantially all sorbed gases and to form a substantially gas free, clay-like precursor material. The precursor material is stored indefinitely prior to producing the material into a desired configuration and heating the formed material to cure such material into a stable solid configuration.

Abstract: A method of molding and a mold for making bathtubs are disclosed. The mold includes a mold receptor and a deck insert attached to the mold receptor face. The preferred deck insert has at least one projection designed to reduce the cross-sectional area of a portion of a void between the shell's deck and the deck forming face of the insert. Preferably, the distance from the outer edge of the shell's deck to the outer edge of the projection is about 16% of the length of the deck of the sanitary fixture. The mold receptor receives a shell which has a finish side and a non-finish side. The shell is placed in the mold receptor leaving a void between the non-finish side of the shell and the deck insert of the receptor. The insert is attached to the mold receptor to reduce the cross-sectional area of a portion of the space between the shell deck and mold receptor. A male mold engages the finish side of uhe shell, sealably retaining the shell to the mold receptor.

Abstract: A hinged plastic housing and a process for making same wherein a hinge formed from a deformable lamina is integrated with first and second enclosing members during injection of the plastic material. The deformable lamina is placed between the first mold section and the second mold section of an injection mold unit before the first mold section and the second mold section are clamped together to form injection mold cavities for the first and second enclosing members. The deformable lamina at least partially extends into the mold cavity for the first enclosing member and the mold cavity for the second enclosing member as well as therebetween. The first mold section and the second mold section are then clamped together and a plastic material is injected into the mold cavities and in bonding securement of the deformable lamina. The resultant housing is then removed from the mold unit with the deformable lamina hinge integrated with the first and second enclosing members.

Abstract: According to a method of producing a modular cover, a gate mark made during injection molding and left on a cover can not be seen from a vehicle occupant. A submarine gate is placed in a mold to contact with a surface of a molded modular cover which is hidden when the modular cover is in use. This mold is used to make a cover by one-color injection molding.

Abstract: A method for manufacturing the half body portions of a magnetic tape cassette or the like having an image transfer layer on its outer surface. An image transfer film is placed in a molding cavity, which film includes a base layer, a matting layer, and an image transfer layer. The function of the matting layer is to roughen the surface of the image transfer layer, while allowing easy subsequent peeling therefrom. A molten plastic is injected into the molding cavity against the image transfer layer. After the resulting product solidifies, the product is removed from the molding cavity, and the base layer and matting layer are peeled from the product, leaving the image transfer layer on an outside surface of the product.

Abstract: A method for encapsulating at least a portion of a heat sink insert with plastic material has been provided in which flashing has been eliminated. There is provided a heat sink insert which has a bottom surface, a shoulder portion, and a rib member formed integrally with and extending upwardly from the shoulder portion to define a crush zone. The rib member is deformed to conform with the contour of a cavity formed by the first and second mold plates so as to create a seal between the insert and the cavity. The rib member also serves to compensate for dimensional variations of the insert and the cavity.

Abstract: A magnetic disk cartridge which is free from the difficulty associated with the color of the cartridge being nonuniform in the area of weld lines which are likely to be formed in the injection molding of a colored synthetic resin, thus impairing the external appearance of the cartridge, and to a method of manufacturing the magnetic disk cartridge. In accordance with one embodiment of the invention, a magnetic disk cartridge is provided which is formed by injection molding a molten resin prepared by mixing master batch pellets of SAN resin at least 100 gm/10 min in melt flow rate and natural pellets of ABS resin at least 25 gm/10 min in melt flow rate in a ratio of 1:50 to 1:15 by weight.

Abstract: A reference pin (150) is provided on a bottom die (108) of a molding device (100). A lead frame (3) is carried with a chucking device (120) attached to an X-Y table mechanism (110). A hole (132) is formed in a stage (131) of the X-Y table mechanism. Respective images of the hole and the pin are detected by a TV camera (142) to control the relative position of the bottom die and the lead frame by driving the X-Y stage.

Abstract: In a method for assembling a lead frame between two plate-mold cavity plates, a lead frame that includes a plurality of integrated circuit chips mounted spaced at intervals in a row thereon, is placed on a bottom one of the cavity plates which has a row of cavities spaced apart at the same intervals as the integrated circuit chips, each chip being positioned over a corresponding cavity. The bottom cavity plate is held about horizontal on the base plate of an assembly fixture. Two short guide pins extend upward from the cavity plate, the lead frame having two pilot holes directly above the guide pins. Accurate positioning of the lead frame will permit penetration of the pilot holes by the guide pins.

Abstract: A process for making powder-free medical gloves that are nevertheless easy to don involves first forming a glove on a form by successively dip-coating layers of a coagulant containing acid-soluble powder dispersed throughout, an elastomer, and an antiblocking composition with particles distributed throughout. After curing the elastomer and applying a silicone coating, the glove is removed from the form and treated successively with acid, to dissolve the powder, and with bleach, to reduce blocking. Using this process, high quality natural rubber medical gloves can be produced.

Abstract: A method for encapsulating a seal member insert with plastic material has been provided in which the seal member insert is located precisely in a molded outer housing. There is provided an elongated mold core element having an undercut area at substantially its intermediate area. A first molten plastic is injected around the core element on each side of the undercut area so as to form annular retainer rings. The seal member insert is provided into the undercut area between the annular retainer rings. A second molten plastic is injected around the core element, the annular retainer rings, and the seal member insert so as to form the molded outer housing. The core element is then extracted so as to form a seal-insert molded product. The annular retainer rings serve as wall members so as to prevent the seal member insert from being moved out of the undercut area and into an undesired location when the second molten plastic is being injected.

Abstract: A method of making a molded applique product. A printed applique substrate is formed into a three dimensional shape and placed into a mold whereupon a molten resin is injected into the mold cavity space located behind the formed substrate.

Abstract: A multi-cavity injection mold process, for simultaneously injection molding a plurality of multi-layer articles, having a single hot runner manifold system for the sequential supply of first and second molten molding materials to the cavities of the mold with each of the materials being supplied simultaneously to all cavities in equal quantities. The process also uses a core rod for each cavity in which a concavity is provided, adjacent the entry point of the materials into the cavity, to prevent the first injected material in an injection cycle from being washed from the end of the core rod by the second injected material, the use of a buffer of the first injected material in the neck region of the preform to compensate for variations in temperature of the cavities and material being distributed to different parts of the mold and the use of the first part of the metered quantity of the first to be injected material from the next injection cycle to seal the preform at the end of the injection cycle.

Abstract: Pinhole-free, radiation absorbing, surgical quality latex gloves are formed from homogeneous suspension of natural rubber and high specific gravity metal or metal compound. The suspension is formed under conditions which prevent entrapment of gas in the suspension.