Abstract: An annular die designed to produce polymer foam using only one or more ambient gasses as a blowing agent includes an exiting channel with an exit having a cross-sectional area between about two and about ten times that of a smallest point within the exit channel. The section of the die from the smallest point to the exit is thermally isolated from the rest of the die, and the temperature thereof is independently controlled. In addition, the interior surface of the exit channel is coated with a friction-reducing coating.

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

Abstract: A process for producing a polymer/filler composite material includes a mixture forming step in which there is obtained a mixture of a flake-like filler and a polymer material, and the mean area (L2), mean thickness (d) and volume fraction (c) of the flake-like filler in the mixture satisfy the following equations (1), (2) and (3): 500 nm2≦L2≦100 &mgr;m2  (1) d≦L/20  (2) 0.2d/L≦c≦4d/L  (3), and a deforming step of applying deformation to the mixture at a strain rate of no greater than 10 s−1.

Abstract: An expansion-molded article (foamed body) produced by using foamed and expanded beads, and having open voids has sound absorbing qualities, and can be used as a sound absorbing material. A sound absorbing material which is able to attain a high sound absorption coefficient in a wide acoustic frequency range is provided by a molded article produced by using resin particles, having through hole(s) and a porosity of 45 to 80% in a most densely packed state. The void content of the molded article is 10 to 60%, and the bulk density thereof is 0.01 to 0.6 g/cm3.

Abstract: An improved process for making a structural foamed polymer, a multilayer polymer film, sheet or tube, a pultrusion polymer profile, a compression molded extruded fiber reinforced polymer pre-form, a strand foamed polymer and a SCORIM formed polymer article. The improvement includes the step of dispersing a multi-layered silicate material with the polymer so that the polymer has dispersed therein single layers of silicate material, double layers of silicate material, triple layers of silicate material, four layers of silicate material, five layers of silicate material and more than five layers of silicate material, the volume percent of the one, two, three, four and five layers of silicate material greater than the volume percent of the more then five layers of silicate material. In each of the above embodiments an important benefit of the instant invention is the orientation of the plane of the layers of silicate material.

Abstract: A pair of form keys and a method for forming reverse drafts in foam parts are disclosed. A male form key is reciprocally mounted in a first mold half in a retracted position. A female form key is rotatably mounted in a second mold half in a neutral position. The first mold half includes a first drive pin that when engaged, moves the male form key into engagement with a foam sheet to form an undercut as the first and second mold halves are closed. The first mold half also includes a second drive pin that engages the female form key as the first and second mold halves close rotating the female form key into engagement with the foam sheet and the male form key. After closure of the mold and the product is formed, the mold is opened. As this occurs, the drive pins are disengaged and the male form key retracts and the female form key rotates to their neutral positions. The formed product may then be stripped from the mold while maintaining the reverse draft or undercut.

Abstract: An injection assembly for an injection moulding machine, comprising a screw (2) mounted in a plasticising cylinder and an injection piston (8) which moves the screw (2) in the longitudinal direction and which is mounted in an injection cylinder, wherein there is provided a supply conduit for the injection cylinder having a control valve (13) which can be shut off and there is provided an additional conduit (14) which by-passes the control valve (13) and in which are arranged a device (17) for reducing the amount of the pressure fluid flowing to the injection cylinder (7) and possibly a device (16) for reducing the pressure.

Abstract: This disclosure relates to a method for making a polymeric article mold, a method for making a polymeric article with that mold, and improved surface topography features for a polymeric article. A prototype article is formed and then coated with a thin conductive layer. The coated prototype article is then electroformed until nickel plated to a sufficient depth to define a nickel plating tool. After the prototype article has been removed from the mold face of the nickel tool, the tool can be used as a mold for forming finished polymeric articles which replicate the original prototype article. The use of fine topography features such as a dense upstanding stem array on the surface of the prototype article facilitates accurate and complete electroforming by increased surface area presentation. The disclosure also presents improvements to microreplicated surface structures such as stem arrays.

Abstract: Using a new molded foaming apparatus wherein chambers 13 and 14, independent from a cavity 4, are formed at the rear sides of a set of dies 2 and 3 for molding a molded foam product, so as to supply such utility fluid as air and steam to the cavity 4 through first openings 30 independently from the chambers 13 and 14, various problems created when forming vent holes are fundamentally solved, and at the same time dispersion of filling density to be caused by not forming vent holes is prevented by supplying the material beads to the cavity 4 while maintaining the pressure in the cavity 4 at a predetermined minus pressure with respect to the pressure in the material tank using the first openings 30.

Abstract: An apparatus and method for molding three-dimensional articles having interstitials. The article has elongate elements and interstitials between the elongate elements. The interstitials may extend entirely through the article, or intercept only the periphery of the article. The article may be formed by injection molding, using two or more mold segments, each having elongate members. The mold segments are separated from each other in a separation direction. The separation direction is parallel to the elongate members of the mold segments and/or the elongate elements of the article. The method and apparatus according to the present invention is useful for making a static mixer, heat exchanger or similar article.

Abstract: A method for making a multi-layer expanded shoe sole includes the steps of (a) molding a first foamable material to form a first unexpanded blank and cooling the first unexpanded blank to a low temperature to harden the first unexpanded blank, (b) molding a second foamable material to form a second unexpanded blank and maintaining the second unexpanded blank at a high temperature such that the second unexpanded blank is in a softened state, and (c) stacking and thermal molding the first and second unexpanded blanks in a mold at a molding temperature to permit the first and second unexpanded blanks to undergo a reaction for cross-linking and expansion.

Abstract: A process for producing a multi-layered article having a soft, leather-like feel comprising first introducing into a suitable mold a first liquid formulation designed to produce the top elastomeric layer on the finished article. A release agent is then applied on the elastomeric layer in the area where it is desired not to have adherence of the elastomer to the foam. Before the elastomeric layer is completely cured, a second liquid foam producing formulation, designed to produce a soft foam, is poured into the open mold. The elastomeric layer of the resulting article is integrally attached to the foam in the areas not containing the release agent.

Abstract: A cellular molded article in a mold pattern having a 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 the metal mold, and a producing method thereof are provided. The cellular molded article in a mold pattern having the surface skin and a producing method thereof, in which, at least a face of the surface skin material, which contacts the metal mold, is an olefin thermoplastic elastomer sheet which is composed of an olefin resin without containing a polyethylene resin as its matrix, and pre-expanded beads, which are employed for an expansion molding in a mold pattern, are pre-expanded beads of an olefin resin.

Abstract: A fiber-reinforced, polymeric implant material useful for tissue engineering, and method of making same are provided. The fibers are preferably aligned predominantly parallel to each other, but may also be aligned in a single plane. The implant material comprises a polymeric matrix, preferably a biodegradable matrix, having fibers substantially uniformly distributed therein. In preferred embodiments, porous tissue scaffolds are provided which facilitate regeneration of load-bearing tissues such as articular cartilage and bone. Non-porous fiber-reinforced implant materials are also provided herein useful as permanent implants for load-bearing sites.

Abstract: Non-flying plastic microballoons are produced by bringing unexpanded, expandable plastic microballoons, which have been heated to a temperature lower than an expansion starting temperature thereof, and a mixture of a wetting agent and gas, the mixture having been heated to a temperature at least equal to the expansion starting temperature of the expandable plastic microballoons, into contact with each other to cause expansion of the expandable plastic balloons, and then cooling the resulting expanded plastic balloons.

Abstract: A process of making a high precision microcontact printing stamp in which an elastomeric monomer or oligomer is introduced into a mold wherein a photoresist master imprinted with a microcircuit design in negative relief is predisposed. The monomer or oligomer is cured at a temperature no higher than about ambient temperature whereby a distortion-free microcontact printing stamp having the microcircuit design of the photoresist master in positive relief is formed.

Abstract: A process for producing solid, porous graphites which provides a more uniform density gradient throughout the ultimate product. The process utilizes a pressure drop during processing in order to induce boiling and varies the processing pressure between an initial pressure which exceeds 1000 psig and a final processing pressure which generally exceeds the initial pressure. The particular processing techniques employed allow additional viscosity manipulation as well as improved density gradient characteristics in the ultimate product. The final products have bulk thermal conductivities in the range from 90-300 W/mK with apparent densities ranging from about 0.678 g/cc-1.

Abstract: In order to make weather seals from closed cell elastomer foam material, molten plastic is extruded over a substrate of the foam material. Surface reactions during extrusion are avoided by continuously pulling the substrate through an oven chamber to degas (and remove moisture from) the material at least on its outside to a limiting thickness of the order of 10-30 mil to form a skin or crust. The extrusion of the over-coating is carried out to form a sleeve while the substrate is still hot. Since the skin is a degassed region on the outside of the foam substrate, reactions which may cause blistering and prevent the extrusion of a smooth and firmly adhering skin are avoided. The substrate material is preferably a thermosetting EPDM rubber closed cell foam, and the over coating material is a thermoplastic elastomer (TPE).

Abstract: A method for making an expanded shoe sole includes the steps of (a) molding a first foamable material to form an unexpanded sole blank, and cooling the unexpanded sole blank to harden the unexpanded sole blank, (b) positioning the hardened unexpanded sole blank on a first mold, (c) heating a second mold to a molding temperature, (d) positioning assembly of the hardened unexpanded sole blank and the first mold in the second mold, (d) filling a second foamable material in the second mold prior to expansion and cross-linking of the hardened unexpanded sole blank, and (e) thermally molding the second foamable material and the hardened unexpanded sole blank in the second mold.

Abstract: A process for injection-foaming a thermoplastic resin by using an injection molding machine with a two-stage-compression screw, injecting a physical foaming agent into the cylinder of the machine at a pressure lower than the storage pressure of the physical foaming agent, mixing it with a melted resin and expanding the volume of the cavity of the mold at the time of injection, and an injection molding machine and resin composition suitable therefore.