Abstract: A method for producing a block having a flat bottom, a flat top which is parallel to the bottom and sidewalls which extend between the bottom and the top is disclosed. At least three cooperating mold parts are assembled on a first plate to produce assembled mold parts having interior surfaces which conform with the shape of the sidewalls of the block and flat, coplanar tops and bottoms. The assembled mold parts are clamped together, and a high slump concrete which is hardenable by hydration of cement therein is charged and worked as required into close proximity to the interiors of the mold parts and to the plate inside the mold parts. A foamable composition capable of forming a body of a thermoset, closed cell, urethane foam having a density of about 10 to 60 pounds per cubic foot which fills the interior of the assembled mold parts above the concrete therein is then charged, and a second plate is clamped over the tops of the mold parts.

Abstract: An automobile trim has a trim body (a base layer) formed of a rubber composition and having a design surface, a decorating layer formed of a thermoplastic elastomer composition and thermally bonded integrally with the design surface of the trim body. A thermal bonding layer is formed of a thermoplastic resin composition and interposed between the decorating layer and the trim body so that the decorating layer is thermally bonded integrally with the trim body through the thermal bonding layer. The thermal bonding layer has a thickness to an extent not to prevent bending flexibility when the trim is attached to a vehicle body. In another example, a cushion layer is laminated on the trim body and formed of sponge rubber of EPDM, a decorating layer is laminated on the cushion layer and formed by foaming olefin thermoplastic elastomer, and an olefin bonding layer for bonding the cushion layer and the decorating layer.

Abstract: The invention provides in-mold decorated articles and methods to form the articles. The in-mold decorated articles include a polymeric portion having a substrate material adhered to a surface of the polymeric portion. The substrate material may be, for example, a film or a fabric. In some embodiments, the polymeric portion may be a foam and, particularly, a microcellular polymeric material. The articles are formed by injecting a mixture of blowing agent and polymeric material into a mold cavity in which the substrate material is disposed, so that the substrate material is forced against a wall of the mold cavity. The blowing agent, which in certain preferred cases is a supercritical fluid, decreases the viscosity of the polymeric material and, therefore, enables reductions in injection pressures and temperatures.

Abstract: In a method for producing a trim article (1), the interspace between a sheet-like decorative material (5) and a carrier (3) is foam-filled. There is provision, during foaming, for the decorative material (5) to be pressed sealingingly onto the interior-side surface of the carrier (3) so as to run around the region to be foam-filled. In this case, the discharge of the air to be displaced during foaming can take place through the foam-tight, but, at least in regions, not gas-tight structure of the carrier (3). For this purpose, the carrier (3) can be gas-sealed in regions by the local compression of an intrinsically gas-permeable unprocessed part before introduction into the foaming die. Also disclosed is a trim article capable of being produced according to the method.

Abstract: Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.

Abstract: The present invention relates to a method of manufacturing a low pressure injection type RIM mold and a product molded using the mold, wherein manufacturing time is reduced by simplifying manufacturing processes and the precision of a product is prevented from being lowered.

Abstract: A method of forming a prosthetic residual limb test socket utilizes an adapter bracket having generally smooth sidewalls in which a corresponding plurality of removable posts are received. The adapter bracket is secured to a model of the residual limb of a patient, and a socket forming material is applied about at least a portion of the model and the adapter bracket. The socket forming material covers the plurality of removable posts but not the lower mounting face of the adapter bracket. The adapter bracket is removable and reusable. In a further aspect, a method is provided for forming a prosthetic residual limb socket based upon a test socket, in which a casting anchor is positioned within the test socket, the casting anchor being engaged with an alignment member extending out through a hole in the test socket. A molding material is introduced into the test socket so as to at least partially encase the casting anchor, and the molding material is allowed to set to form a model.

Abstract: A press for rigid foam sheets with continuous adjustment of the spacing between the two press plates (1,3), in particular for sandwich panels with an upper and lower outer layer and, located therebetween, a core of rigid polyurethane foam. The lower press plate (3) is here moved into a preselected position corresponding to the panel thickness to be foamed by means of synchronously rotating threaded lifting spindles (4), assisted by weight-compensating cylinders (5). Short-stroke cylinders (6) are provided between the heads of the threaded lifting spindles (4) and the lower press plate (3). Said short-stroke cylinders have the function of dissipating the moulding force which has arisen due to foaming by moving the press plate (3) a very small stroke downwards. It is also possible, instead of the short-stroke cylinders (6), to install an air cushion system, which has a stroke of approx. 1 mm, between the press plate and the heating plate. This stroke is sufficient to dissipate the foaming pressure.

Abstract: An apparatus and method for manufacturing ultra-fine particles using an electrospray device is disclosed. One or more capillary provided at its tip with a nozzle is positioned within a guide duct and precursors such as metal organic materials and metal halogen compounds, or nonvolatile substances or volatile substances are supplied to the capillary. Voltages are applied to the capillary and the guide duct, respectively, so that a voltage difference is generated therebetween and the highly charged liquid droplets from the capillary are sprayed. The sprayed liquid droplets are carried along the guide duct together with carrier gas injected into the guide duct. When heat energy is applied to the liquid droplets, chemical reactions of the liquid droplets occur. A collecting plate positioned in front of the guide duct collects ultra-fine particles formed by the chemical reactions.

Abstract: Aspects of the present invention include interior vehicle trim panel having a sprayed expanded polyurethane layer and method of making same. In at least one embodiment, the method of making the vehicle interior trim panel comprises providing a skin layer on a spray tool, spraying expandable polyurethane reactive components onto the skin layer to form a resilient layer, and securing a rigid substrate on the resilient layer, such that the resilient layer extends between and connects the skin layer with the substrate to form the vehicle interior trim panel.

Abstract: The present invention is a process of manufacture of one or more polysaccharide beads, comprising generating an aerosol of an aqueous polysaccharide solution, cooling the droplets of said aerosol in air to initiate gelling thereof and collecting droplets as gelled beads in a liquid or on a surface, characterised by adding a hydrophilic vapour pressure-lowering agent to said polysaccharide solution.

Abstract: The present invention solves the problems left unaddressed by the prior known processes by providing a method to produce foamed-thermoplastic films of sufficient strength for use in consumer trash-bag applications utilizing high strength thermoplastic resins. Most broadly, the present invention comprises a blown-film bag formed from a material comprising a matrix of foamed polyolefin-based film and gaseous cells formed from a foaming agent.

Abstract: Biodegradable molded articles; a process for producing the same: and compositions for foam molding packed in a packaging film bag to be used in the production. A bowl-type container(10a), which is one of the biodegradable molded articles as described above, consists of a bowl body(11a) comprising starch as the main component and a coating film(12) having at least hydrophobic properties and comprising a biodegradable plastic as the main component which is bonded to the surface of the bowl body(11a). This bowl body(11a) is formed by steam-foaming molding a material to be molded which is in the form of a slurry or a dough containing starch and water. The coating film(12) is closely bonded to the surface of the bowl body(11a) either directly or via an adhesive layer. Compositions for foam molding packed in such packaging film bags can be easily stored and molded.

Abstract: A composite material for vehicle hulls and a hull molding process comprising a gel coat, a skin coat, a bulk fiberglass layer and adhesive applied to a top mating surface and a bottom mating surface within a top mold and a bottom mold, wherein the adhesive forms a connector. The two molds are placed together, and after the adhesive sets, foam is introduced into at least one cavity formed when the molds are brought together. The molds remain closed while the foam is introduced.

Abstract: Method for the production of a biocompatible polymer-ceramic composite material with a predetermined porosity, designed and determined a priori, which includes a first phase (a) of the production of a suspension of a bioceramic material in distilled water, a second phase (b) in the which a compact of the bioceramic material containing a desired quantity of water is obtained from the suspension, and a third phase (c) in the which the compact is mixed with a polymeric material and/or a liquid monomer.

Abstract: A continuous process for manufacturing a sound absorbing tile made from a slurry including, quick setting cement, water, fibers and foaming agent, the process including the steps of (i) mixing cementitious material, water, foaming agent but without incorporation of prefabricated foam with fibers into a slurry; subsequently; (ii) injecting and distributing air into the slurry of step (i) to form a cellular slurry; subsequently; (iii) forming tiles or precursor products of tiles from the cellular slurry; and finally; (iv) allowing the cellular slurry to set into the desired tile or a precursor thereof.

Abstract: A method for manufacturing resin films includes steps of mixing PU resin and hydroxyl compound to become a first-kind first-phase mixture, and of mixing a pigment with a foaming agent to become a second-kind mixture, of injecting the first-kind mixture into a kneading device to get mixed and kneaded to become a first-kind second-phase mixture, of sending the first-kind second-phase mixture into a second kneading device to get a first-kind third-phase mixture, and the second-kind mixture and the first-kind third-phase mixture both sent into a conveyer to get a third-kind mixture, and the final step is to send the third-kind mixture into a coating device for coating the third-kind mixture on a substrate cloth to get a resin film of an original color and fresh brilliance.

Abstract: Plant for manufacturing latex foam layer of unlimited length and having lower and upper recesses. A plurality of laying planes provided with lower protuberances proceeds between an injection station and a layer removing station. Foam provided with lower recesses is directed towards a vulcanizer between the injecting station and the removing station. A plurality of upper plates, each provided with protuberances, is lowered, one by one, on the foam layer to impress upper recesses before the foam layer enters the vulcanizer. The plates, placed on the foam layer, have their ends shaped to avoid any penetration of steam condensation drops. Upper plates release their weight to fixed supports of the planes to which they are bound until they leave the vulcanizer. The return of the plates from the extraction station towards the new cycle of moulding is independent of the operating system of the planes.

Abstract: A process for producing a polyurethane grinding tool is provided, the process including a step of mixing one or more types of polyol component selected from the group consisting of polyether polyols and polyester polyols with inorganic abrasive grains, a step of mixing an organic polyisocyanate component with inorganic abrasive grains, a step of uniformly mixing the polyol component mixed with the abrasive grains and the polyisocyanate component mixed with the abrasive grains by means of a rotary-static mixer, and a step of molding the mixture thus obtained by reacting the mixture in a mold.

Abstract: A method for forming a foamed product integral with a sheet of covering material utilizing a forming apparatus which comprises a first die, a second die housed within the first die and having air-ventilating holes, and a third die adapted to be combined with the first die, to thereby provide a forming cavity between the second die and the third die, the method comprising the steps of preparing a three-dimensional, air-permeable trim cover having a two layer structure comprising a layer of foamed material and a sheet of covering material laminated with the foamed material layer, putting the trim cover on the second die such that the sheet of covering material is facing the second die, applying vacuum to the trim cover through the air-ventilating holes of the second die to draw the trim cover onto the second die, causing the third die to be combined with the first die to define the forming cavity in cooperation with the first die, thereafter stopping the applying of the vacuum to the trim cover, and pouring exp