Patents Examined by Allan R. Kuhns
  • Patent number: 7160491
    Abstract: An automotive vehicle frame reinforcement system has a skeleton member designed to be secured to a vehicle frame, such as a roof or pillar section. An expandable material, such as an epoxy-based reinforcing foam, is disposed on the skeleton member. Once the system is attached to the frame, the foam expands and cures during an automobile assembly operation, bonding the reinforcement system to the frame. As a result, the reinforcement system provides enhanced load distribution over the vehicle frame without adding excessive weight.
    Type: Grant
    Filed: May 24, 2005
    Date of Patent: January 9, 2007
    Assignee: L&L Products, Inc.
    Inventors: William J. Barz, Thomas L. Coon, Michael J. Czaplicki
  • Patent number: 7160096
    Abstract: A perforation apparatus particularly useful for creating perforations in a foam-in-bag cushion and methods of using such apparatus are provided. The perforation apparatus is comprised of a frame, a main shaft mounted in the frame so as to be rotatable about a central axis, at least one needle roller coupled to the main shaft such that rotation of the main shaft moves the needle roller through a predetermined arc of motion out of and into an operative position adjacent to and perforating a plastic film advancing past the needle roller, and an actuator coupled with the main shaft and operable to rotate the main shaft so as to move the needle roller. Optionally, the apparatus is further comprised of at least one backup roller. Methods of preparing and perforating a foam-in bag cushion using the perforating apparatus are also provided.
    Type: Grant
    Filed: October 24, 2003
    Date of Patent: January 9, 2007
    Assignee: Sealed Air Corporation
    Inventors: Michael Knaak, Andy Tyler, Dave Carson, Daniel C. George
  • Patent number: 7153456
    Abstract: A process is described for making gourd molds useful in the production of decorative ceramic and other articles which bear the textures of the gourd interior. Articles produced may also serve as models for use in the manufacture of production molds. Steps in making the gourd molds include selection, cutting, and removal of pulp; steps in using the gourd molds include treating with a release agent, casting, and removal of the gourd mold from the molded article.
    Type: Grant
    Filed: April 26, 2002
    Date of Patent: December 26, 2006
    Assignee: GourdCraft Originals, Inc.
    Inventor: Priscilla Ann Wilson
  • Patent number: 7150844
    Abstract: A method of manufacturing a stamper/imprinter for use in patterning of a recording medium comprises sequential steps of: (a) providing a substrate/workpiece comprising a topographically patterned surface including a plurality of projections and depressions corresponding to a pattern to be formed in a surface of the recording medium; (b) forming a thin release layer in conformal contact with the topographically patterned surface by means of a dry process; (c) forming a thicker layer of a material in conformal contact with the thin passivation layer on the topographically patterned surface; and (d) separating the thicker layer of material from the topographically patterned surface to form therefrom a stamper/imprinter including an imprinting surface having a negative image replica of the topographically patterned surface, separation of the thicker layer of material from the topographically patterned surface being facilitated by the thin release layer formed by the dry process.
    Type: Grant
    Filed: October 16, 2003
    Date of Patent: December 19, 2006
    Assignee: Seagate Technology LLC
    Inventors: Neil N. Deeman, Hong Ying Wang, Gennady Gauzner, Nobuo Kurataka
  • Patent number: 7150614
    Abstract: Disclosed is an apparatus and a corresponding method for producing a continuous foamed extrudate product in which the extrusion and initial expansion of the foamed extrudate is conducted within a chamber under a partial vacuum. The foamed extrudate is then removed from the chamber through an orifice submerged within a liquid baffle. The dimensions of the foamed extrudate are monitored as it approaches the orifice and, if necessary, the effective sizing of the orifice is adjusted through the movement of a pair of side gates and a single vertical gate arranged external the orifice to match opening to the foamed extrudate and impede the flow of liquid into the chamber through the orifice.
    Type: Grant
    Filed: December 18, 2003
    Date of Patent: December 19, 2006
    Assignee: Owens Corning Fiberglas Technology, Inc.
    Inventor: Robert L. Sadinski
  • Patent number: 7147808
    Abstract: A method of making a vehicle part includes spraying material proximate a surface of a tool to form a skin layer, and spraying material onto the skin layer to form a resilient layer. The method further includes removing the skin layer and the resilient layer from the tool and positioning the layers in a mold. Next, the method involves applying material onto the resilient layer to form a rigid substrate on the resilient layer.
    Type: Grant
    Filed: July 6, 2004
    Date of Patent: December 12, 2006
    Assignee: Lear Corporation
    Inventors: Glenn A. Cowelchuk, Robert J. Adams, Kenneth W. Shaner, Nelson E. Williams, Jr.
  • Patent number: 7144532
    Abstract: The present invention provides blowing agent introduction systems and methods for introducing blowing agent into polymeric foam processing systems. The methods may involve introducing one or more doses of blowing agent into polymeric material in an extruder during a plastication period of a molding cycle. Prior to introduction, a dose is confined in an accumulator which, for example, has a volume defined between an inlet valve and an outlet valve. A control system may receive inputs related to system parameters (e.g., pressure of polymeric material in extruder, axial position of screw in barrel, whether screw is rotating, and the like) and based on the inputs coordinates operation of the valves to confine and introduce the blowing agent dose(s). The introduction systems may be used in discontinuous plasticating processes, such as injection molding and blow molding, and can be particularly useful in processes that use precise quantities of blowing agent.
    Type: Grant
    Filed: October 28, 2002
    Date of Patent: December 5, 2006
    Assignee: Trexel, Inc.
    Inventor: Roland Y. Kim
  • Patent number: 7138078
    Abstract: It is an object of the present invention to provide a method for manufacturing a high-quality foam that can be produced stably on an industrial scale and that affords excellent thermal insulation as a foam with thin cell membranes, which method ensures uniform molten mixture fluidity, which is an essential condition for achieving consistent foam quality, in the manufacture of a foam by mixing starch as one molten polymer compound with another polymer compound having a different melt viscosity, and to provide a foam manufactured by this method. Water is added to and mixed with a plant-derived fibrous material and starch to manufacture a foam of a plastic resin containing as compositional components starch and a plant-derived fibrous material such as pulverized paper, pulverized wood, or the like.
    Type: Grant
    Filed: April 3, 2002
    Date of Patent: November 21, 2006
    Assignee: Tokiwa Printing Inc.
    Inventor: Yutaka Gotoh
  • Patent number: 7138079
    Abstract: Methods for making foamed elastomer gels are disclosed. Chemical foaming agents may be incorporated or gas may be injected into a molten gel and then using heating and cooling techniques and/or additives, gas bubbles are formed and preserved in the cooled and solidified elastomer gel.
    Type: Grant
    Filed: February 11, 2003
    Date of Patent: November 21, 2006
    Assignee: EdiZone, LC
    Inventor: Terry V. Pearce
  • Patent number: 7138077
    Abstract: The invention relates to an installation and a process for the production of foam in a continuous block foam process in which the height of a foam-forming mixture along a conveyor is measured and a correcting variable as a function of deviation of the actual height risen from the standard height is determined.
    Type: Grant
    Filed: August 11, 2003
    Date of Patent: November 21, 2006
    Assignee: Bayer MaterialScience AG
    Inventors: Hubert Ehbing, Holger Zien, Karl-Heinz Dörner, Christian Beck, Hans Frei
  • Patent number: 7135139
    Abstract: A mold assembly for producing a molded object from resin. The assembly includes a cavity configured to be filled with resin to form at least one surface of the molded object into a predetermined shape with at least one transfer surface of the cavity. A molding insertion member is arranged to form another surface of the molded object, and a holding insertion piece is configured to hold the molding insertion member. The holding insertion piece includes a communication path that places a surface of the molding insertion member at a side opposite to the cavity in fluid communication with the exterior of the mold assembly and guides air from the exterior of the mold assembly toward the surface of the molding insertion member.
    Type: Grant
    Filed: January 20, 2004
    Date of Patent: November 14, 2006
    Assignee: Ricoh Company, Ltd.
    Inventors: Toshihiro Kanematsu, Yasuo Yamanaka
  • Patent number: 7132070
    Abstract: A method of manufacturing a polishing pad is described. A mold having a mold cavity therein is provided. At least a strip is buried in the mold. A polymer foam material is injected into the mold cavity of the mold. The polymer foam material is cured to mold the polymer foam material into a molding polymer article. A mold release process is performed to obtain the molding polymer article. The strip on the molding article is removed to form a polishing pad having at least one groove thereon.
    Type: Grant
    Filed: May 14, 2003
    Date of Patent: November 7, 2006
    Assignee: IV Technologies, Co., Ltd.
    Inventors: Wen-Chang Shih, Yung-Chung Chang, Min-Kuei Chu, Lung-Chen Wei
  • Patent number: 7125509
    Abstract: The present invention discloses an apparatus which enables in-situ casts of the feet of a patient to be made whilst the feet support the patient's weight. In particular, two heel supports (28, 29) and two stirrups (38, 39) receive the heels and forefeet of the patient. Each is capable of independent movement being both rotation about the heel-toe axis and movement substantially transverse to that axis. A method of forming a cast of the patient's feet is also disclosed.
    Type: Grant
    Filed: September 13, 2000
    Date of Patent: October 24, 2006
    Inventor: Neil Robert Smith
  • Patent number: 7118793
    Abstract: A foamable structure includes a film shell having a bottom face and a peripheral wall, and a foamable material mounted in the film shell and having a bottom face combined with the bottom face of the film shell, and a peripheral wall combined with the peripheral wall of the film shell. Thus, the film shell is coated on the periphery of the foamable material, so that the film shell is combined with the foamable material rigidly and stably, thereby preventing the foamable material from detaching from the film shell due to a pulling action of an external force.
    Type: Grant
    Filed: October 10, 2003
    Date of Patent: October 10, 2006
    Inventor: Swei Mu Wang
  • Patent number: 7118696
    Abstract: Polymeric structures produced with a controlled number and distribution of small, closed cells. The polymeric structures are characterized by an opaque, whitening appearance attributed, at least in part, to the distribution of closed cells and thus, at least in part, to light scattering resulting from the distribution of small, closed cells or voids. The light scattering thus provides an enhanced whitening effect. The whitening effect may be uniform or non-uniform along the length and width of the structure.
    Type: Grant
    Filed: June 8, 2004
    Date of Patent: October 10, 2006
    Assignee: Milliken & Company
    Inventors: Kirkland W. Vogt, Daniel T. McBride, Robert M. Smith
  • Patent number: 7108819
    Abstract: A tool for embossing high aspect ratio microstructures is provided, wherein the microstructures provide decreased surface reflection and increased transmission through an optical component even at high incident angles. The tool is fabricated by a process that comprises anisotropic etching of columnar pits in a silicon substrate using inductively coupled plasma, followed by isotropic reactive ion etching of the columnar pits to create relatively pointed obelisks. The silicon substrate is then preferably rinsed to remove remaining photoresist prior to vapor depositing a conductive layer thereon. Finally, a metal is electroformed over the conductive layer to form the embossing tool. The embossing tool is then pressed against an optical coating, for example a polymer sheet, to create microstructures having aspect ratios from 1 to 5.
    Type: Grant
    Filed: May 16, 2003
    Date of Patent: September 19, 2006
    Assignee: The Boeing Company
    Inventors: Alan B Harker, Jeffrey F DeNatale, Dennis R Strauss
  • Patent number: 7108814
    Abstract: Touch fastener, molded articles having touch fasteners and methods of making such touch fasteners and articles are provided. The touch fasteners include a sheet form base having an upper face and a lower face; a plurality of male fastener elements, each fastener element having a stem molded integrally with and extending from the upper face of the sheet form base; and a foam or fibrous non-woven material adjacent to the upper face of the sheet form base, wherein at least a portion of the foam or fibrous non-woven material is disposed between at least a portion of the fastening elements.
    Type: Grant
    Filed: November 24, 2004
    Date of Patent: September 19, 2006
    Assignee: Velcro Industries B.V.
    Inventors: Emilio Munoz Herrero, Luis Parellada Armela, Daniel Lee Janzen, Kevin Keith Line, Christopher M. Gallant
  • Patent number: 7105112
    Abstract: A lightweight member is provided for reinforcing, sealing or baffling structures of articles of manufacture such as automotive vehicles. The lightweight member preferably includes a carrier member having a cellular structure and an expandable material disposed thereon.
    Type: Grant
    Filed: October 16, 2003
    Date of Patent: September 12, 2006
    Assignee: L&L Products, Inc.
    Inventors: Michael J. Czaplicki, David Carlson
  • Patent number: 7105113
    Abstract: A method is disclosed for flatproofing a tire and wheel assembly with a flexible, lightweight foam-fill by supplying at least two polyurethane reactive materials to a static mixer. The static mixer mixes the reactants, and a nucleating gas is supplied to the mixed reactants in the static mixer to form a liquid reactant mixture with entrained gas. The reactant mixture is injected into the tire and wheel assembly where the mixture reacts and foams replacing the air in the tire with a flexible, lightweight semi-open cell foam-fill. The resulting foam-filled tire and wheel assembly is then allowed to cure.
    Type: Grant
    Filed: October 16, 2003
    Date of Patent: September 12, 2006
    Assignee: Urethane International LLC
    Inventors: John Danules, Steve Anderson, Van Doesburg
  • Patent number: 7101501
    Abstract: A foamed plastic is cut to form a single-layer polishing pad having a desired rigidity and compressibility. A polishing surface of the polishing pad has a higher density than a mounting surface of the polishing pad. The polishing surface and the mounting surface may have different areas having different densities for achieving desired rigidity and compressibility property. Furthermore, methods of making such single-layer polishing pads are also disclosed.
    Type: Grant
    Filed: May 3, 2005
    Date of Patent: September 5, 2006
    Assignee: IV Technologies Co., Ltd.
    Inventors: Wen-Chang Shih, Yung-Chung Chang, Min-Kuei Chu