Abstract: There is now provided a method for producing a product comprising plastic foam in an automatic molding machine. The method comprises providing a woven fabric on at least one surface of the mold cavity, with the woven fabric comprising a fabric having a fine-mesh woven fabric ply that faces the interior of the mold cavity upon assembly and a coarse-mesh woven fabric ply that is disposed adjacent at least one surface of the mold cavity and beneath the fine-mesh woven ply upon assembly to support the fine-mesh woven ply. The method further provides for introducing beads comprising plastic foam into the mold cavity; contacting the beads with a gaseous heat transfer medium, such as superheated steam; introducing the gaseous heat transfer medium into the mold cavity; flowing the gaseous heat transfer medium along a first surface of the mold cavity; and removing gaseous heat transfer medium along a second surface of the mold cavity; and removing the finished product from the mold.

Abstract: Methods and apparatus for eliminating or reducing a surface skin when producing a flexible polyurethane foam slab are disclosed. The top surface of the chemically reactive polyurethane foaming mixture is heated during and/or after the foaming mixture expands. The heating preferably is conducted so as to prevent a significant temperature gradient from forming between the internal temperature of the foaming mixture and the top surface of that mixture. Preferably, heat is applied so as to heat from the top surface of the foaming mixture in an escalating fashion to higher temperatures as the foam is conveyed along a conveying path away from the foaming mixture dispensing device.

Abstract: The present invention provides a method for producing a multilayer molded article comprising a step of supplying a skin material having at least a foam layer between a pair of a male mold half and a female mold half, supplying a molten thermoplastic resin between the skin material and the molding surface of one of the male mold half and the female mold half, a step of laminating the skin material onto at least a part of the surface of a substrate made from the thermoplastic resin and a step of forming a recess in the skin material laminating region, wherein the thickness, t (mm), of the foam layer in the skin material before molding is 0.6 R or less wherein R represents the minimum radius (mm) of the recess on the skin material laminating side of the substrate in the skin material laminating region of the multilayer molded article.

Abstract: The invention provides a blowing agent metering system and method for use in polymeric foam processing. The system may be used to control the rate of introduction of blowing agent into polymeric material in a processing apparatus to form a mixture having the desired blowing agent weight percentage. The metering system includes a restriction orifice which is positioned in a pathway between a blowing agent source and a blowing agent port within a foam processing apparatus. The metering system measures the pressure differential as blowing agent flows across the restriction orifice from the source to the port and may also measure the temperature of the blowing agent at one or more locations. Using a pre-determined relationship between the flow rate, the orifice dimensions (e.g., length, diameter) and the measured variables (e.g.

Abstract: Disclosed is a method of manufacturing a mechanically and chemically embossed surface covering having selectively textured surfaces. The method includes forming a web coated with a wear layer. The coated web is heated to a temperature at which the wear layer is cured, the foam layer expands, and the pattern is chemically embossed to form a surface covering having foamed regions and nonfoamed regions. The temperature gradient of the surface covering is adjusted such that there is a temperature gradient difference between the foamed and nonfoamed regions. A surface texture is then mechanically embossed into the wear layer and selectively set onto the wear layer substantially overlying the non-foamed regions.

Abstract: A method of forming an injection molded epidermal abrasion device includes depositing mold material on an epidermal abrasion device. The epidermal abrasion device is separated from the mold material to yield a mold. An epidermal abrasion device is then formed within the mold. The epidermal abrasion device may include a matrix of isotropically etched structures having isotropically etched sidewalls positioned between wide bases and narrow tips, each isotropically etched structure having a vertical height of at least 20 &mgr;m. The matrix of isotropically etched structures may define a matrix of pyramids.

Abstract: A method of making a mold directly from the object to be molded is disclosed. The object is placed within a walled enclosure having a closed bottom and open top. A plurality of elongated metal rod elements is vertically introduced and packed into the enclosure in vertical contact with said object and side by side contact with one another. An infiltration agent, such as a liquid resin or metal, is introduced over the elongated metal rod elements and allow to permeate into the spaces between the rod elements. The mass consisting of the liquid infiltration agent and the elongated metal elements is allowed to solidify into a mold which is removed from the object.

Abstract: A method of making an acoustic device in the form of a loudspeaker drive unit having a resonant panel-form member adapted to provide an acoustic output when excited with bending wave energy, comprising forming a resilient suspension for the panel-form member by molding and simultaneously fixing the resilient suspension to the panel-form member.

Abstract: The invention is concerned with a core material suitable for use in closed mould systems, based on at least one fibrous web containing a foam-structure within the web, said core material having a compression-resistance of greater than 90% at 1 bar pressure, and a permeability for resin of more than 5×10−9 m2.

Abstract: Polypropylene resin pre-expanded particles having an expandability of 1.0 to 1.

Abstract: A process for forming a coating layer on the surface of a molded product by boiling a coating solution in a closed metal mold. The molding process includes depressurizing the cavity of the metal mold, boiling a coating solution in the cavity and injecting a urethane material into the cavity under reduced pressure.

Abstract: In a process and apparatus for producing hollow bodies from plastic material which are at least partially filled with foam, firstly a preform is expanded in a blow molding mold by an increased internal pressure to form a hollow body which is then at least partially filled with foam plastic beads. The compressed beads are introduced into the expanded hollow body while still within the mold, under a pressure which is higher than the pressure obtaining in the hollow body. The beads in the hollow body experience a relief of pressure which results in the increase in volume of the beads and which provides for at least very substantial filling with a foam of at least a delimited part of the volume in the hollow body.

Abstract: A method is disclosed for modifying the physical characteristics of a web which involves passing the web between at least one pair of interengaged rolls to incrementally stretch the web, and then withdrawing the incrementally stretched web from between the rolls under tension. A web modified according to the disclosed method has desirable breathability and liquid impermeability, as well as extensibility and a soft, cloth-like textured surface. One embodiment of the present invention provides a breathable web comprising a microporous film exhibiting an MVTR of at least about 2000 g/m2/24hr, a dynamic impact value of less than about 10 g/ m2, a bubble pressure at least about 45 psi, and an air flow of at least about 2 liters/m2/s.

Abstract: A method of producing a heat insulating board comprising two opposed facings and a core made of a rigid synthetic resin foam, which comprises spraying or injecting a foam mix for the rigid synthetic resin foam into the space between the opposed face materials and expanding and curing the foam mix, wherein the foam mix comprises a particular polyol, a polyisocyanate, a foam stabilizer, a catalyst and a blowing agent, wherein the polyol contains a polyether polyol having a hydroxyl value of at most 84 mgKOH/g and an oxyethylene group content of at least 40 wt %; a polyether polyol which is obtained by adding a cyclic ether to an amine compound and has a hydroxyl value of from 250 to 900 mgKOH/g; and fine polymer particles stably dispersed in the polyol.

Abstract: The invention provides a counter-rotating extrusion system for processing foam material. The system is designed to introduce a physical blowing agent into the extruder, thoroughly disperse the blowing agent within the polymer melt and, preferably, to maintain relatively high pressures downstream from the point of blowing agent introduction. High quality polymeric foams, including microcellular foams, can be produced using the extrusion system. The system is particularly suitable for the production of foams using shear sensitive and degradable materials, such as PVC.

Abstract: The invention provides a blowing agent delivery system and method for introducing a blowing agent into a polymeric foam processing system. The delivery system is designed to introduce blowing agent into polymeric material within an extruder when polymeric material is being plasticated, for example, during the plastication period of an injection molding cycle. The rate of introduction of blowing agent into polymeric material may be coupled to the flow rate of polymeric material in the extruder to ensure precise control over blowing agent percentage in the resulting mixture of polymeric material and blowing agent. The delivery system is also designed to prevent the introduction of blowing agent into the polymeric material when polymeric material is not being plasticated, for example, during the injection period of an injection molding cycle. The delivery system may be used in conjunction with discontinuous systems including injection molding or blow molding systems.

Abstract: A method is provided for manufacturing molded simulated stone and wood architectural articles for buildings and homes. The method incorporates a unique mold assembly including a resilient silicone rubber mold supported within a rigid mold cradle/foundation, and a vented lid having a High-Density Polyethylene (HDPE) interior surface. The silicone rubber mold is initially treated with a liquid polyester gel coating that is cured and then coated with an acrylic/vinyl ester back coating. Once the back coating is cured, a predetermined volume of a modified high-density, natural mineral fiber-reinforced, 2-component hybrid polyurethane liquid expanding composition is dispensed therein and the mold is covered with the vented lid. The system is pressurized and heated to produce a molecularly-fused, lightweight rigid article having the desired architectural shape.

Abstract: A method of producing a composite plastic molded article having at least one layer of web material and a plastic body, includes placement of the web material between mold halves of an injection mold and deforming the web material through closing of the mold. Subsequently, negative pressure is applied on one side of the web material and/or excess pressure is applied on its other side, so that the web material bears upon a mold half. Plastic mass is then introduced into the opening mold in such a way that the feed rate of the plastic mass and the opening speed of the injection mold are coordinated with each other. Once a certain opening gap has been reached, the mold is closed and the plastic article is embossed.

Abstract: A dielectric lens which is produced by injection molding of an expandable material consisting of a synthetic resin, a foaming agent and a dielectric constant conditioner. The expandable material is injected into a cavity of a foaming mold up to at least about 80 percent by weight and at least about 100 percent by volume of the capacity of the cavity and is foamed at an expansion ratio of not more than about 1.3. During the foam molding, the surface of the foam-molded body is solidified to be a radome layer. Then, the foam-molded body is transferred from the foaming mold to a shaping mold, in which the foam-molded is cooled down naturally. Further, a fitting tab is provided integrally with the foam-molded body at the edge of the radome layer.

Abstract: An apparatus for extruding pencils and a method of using the apparatus. A core material (6) is extruded from an extruder (1) and forms a catenary loop in a cooling zone (4). The core material is carefully cooled at ambient temperature before being cooled and straightened at a cooling unit (5). The core material is coated in a crosshead and die assembly (8) with sheath material extruded from extruder (10). In a further cooling zone (12) the sheath material expands under the action of a blowing agent and the extrudate is sized by a calibrator (13).