Abstract: The present invention relates to a method for producing a plastic composite element (1), in particular as an interior lining element for a motor vehicle, with an outer covering (2) being lined with a foamable plastic, characterized in that the outer covering (2) is lined at least partially with a flexible foam (3), that the flexible foam (3) is subsequently lined with a rigid foam (5) with a separating means being placed thereinbetween, and that a shaped part (4) which can be prefabricated is used as the separating means which by virtue of the mechanical properties of its material and/or its shape prevents the rigid foam (5) from penetrating the flexible foam (3) and/or prevents a deformation of the outer covering (2), and such a plastic composite element (2).

Abstract: The object of the present invention is to produce plural resin forms at one time with stability by dividing resin starting material continuously in a short time and with the same residence time into plural parts having desired amounts of resin and discharging to solidify them. The producing method is comprising, providing a liquid partition on the die land and/or die lip of a coat hanger shaped die along with the flow direction, introducing starting material for resin into said coat hanger shaped die and dividing it into plural parts and then discharging and solidifying on the adherent.

Abstract: A method and an apparatus for manufacturing a polyurethane foam injected with strand mats. After a polyurethane foam solution is sprayed on the strand mats, the strand mats are moved upward and downward by prominences and depressions and then intermittently pressed by a pressing device, thereby the air in the strand mats being exhausted to the outside. Therefore, the polyurethane foam solution uniformly permeates into the strand mats. As a result, the insulating effect and mechanical strength of the polyurethane foam are increased, uniform surface with no air spaces is obtained, the mechanical properties are made uniform, and shrinkage, cracking, distortion and the like are prevented under a super-low temperature such as less than ?165° C.

Abstract: The invention provides a blowing agent delivery system for introducing a blowing agent into a polymeric foam processing system. The delivery system is designed to discontinuously introduce blowing agent from a continuous source into polymeric material within an extruder. The system, thus, may improve control over blowing agent delivery in discontinuous polymer processing systems such as injection molding or blow molding. In some embodiments, the blowing agent delivery system selectively directs blowing agent flow from the source to the extruder barrel, or through a bypassing passageway. In this manner, blowing agent may be continuously supplied by the source but discontinuously injected into the extruder barrel. During use, the delivery system may cause blowing agent to flow through the bypassing passageway, for example, when the screw stops plasticating polymeric material.

Abstract: A method of molding a composite structure of a polymeric preformed skin with tightly radiused features and a polymeric foam body is provided. The method includes providing a mold cavity having a first edge; placing the preformed skin in the mold cavity with a preformed first edge of the preformed skin adjacent to the first edge of the mold cavity; heating the preformed skin adjacent the first edge; exposing the first edge to a vacuum to reform the preformed skin first edge to be adjacent the mold cavity first edge and injecting a foam polymeric material into the mold.

Abstract: A method is provided for molding an article (10) that includes a polymer (100) such as an epoxy resin, reinforced by fibrous material (102) such as fiberglass which is embedded in the polymer material, especially for a hollow article such as a shell. The method includes placing spacers (42, 44) in a mold cavity (30), where the spacers conform closely to the cavity surface and leave a free, or empty volume (64) within themselves. Foamable material (60A) is placed in the free volume and allowed to expand and push the spacers toward the cavity walls while forming a foam core (70) within the spacers. The mold is opened and the spacers and foam core are removed. Next, the foam core is covered with an impervious layer and the fibrous material (72) is wrapped around the foam core. The foam core is placed back in the mold, with the fibrous material spacing the foam core from the walls of the mold.

Abstract: The invention is a decorating medium, system and method for producing relief art on substrate surfaces. The decorating medium is an acrylic emulsion based medium containing an expandable polymer which expands the medium upon heating. The acrylic emulsion is produced with a mixture of an acrylic binder and an acrylic thickener or a cellulosic thickener combined in the appropriate range to obtain a medium rheology suitable for controlled application of the medium to the substrate surfaces. The decorating medium is applied to a substrate surface in a desired pattern either directly from a storage bottle or tube equipped with a nozzle or with an applicator such as a brush, a sponge, a knife or spatula. The desired pattern is achieved by free hand or by using a stencil or mask. After the decorating medium is applied to the surface of the substrate in the desired pattern, the medium is cured and heated. The heat causes the medium to expand and creates the relief art on the surface of the substrate.

Abstract: A process for manufacturing a capital for an architectural column. The inside of a mold for an architectural column is lightly coated with a mold release. A first opening of the mold is placed upon a surface, and a plug is positioned on the surface within the first opening. Through another opening foam is poured around the plug. After the foam has hardened, the mold is removed from the surface. All other openings in the mold are securely covered. Then an elastomer is introduced into the mold, and the mold is rotated about multiple different axes. The introduction of the elastomer is repeated after the prior coating created by the introduced elastomer has become tacky but before the prior coating has become firm. After the final coating of elastomer has become tacky but not firm, foam is introduced into the mold.

Abstract: The invention relates to the production of foamed sandwich elements including skins joined by a frame. In applying the foam in a cassette formed by the frame and one of the skins the invention provides for use of an applicator having a two-dimensional movable discharge orifice.

Abstract: A combination fastener and foam sheet having enhanced fastener retention and methods of forming a foam sheet are provided so that the fastener is not easily removed from the foam sheet when an outward force is applied thereto. The combination preferably includes a foam sheet including a fibrous material and urethane foam material abuttingly contacting and substantially surrounding the fibrous material so that the fibrous material is substantially contained within and retained by the urethane foam material. The combination also, preferably includes a fastener having threaded portions positioned within the foam sheet so that the threaded portions are retained in the foam sheet and are not easily removed when an outward force is applied thereto. The foam sheet preferably also has a strengthening material such as glass also substantially surrounded by the urethane foam.

Abstract: A door or other entryway component of synthetic resin composite construction and closely resembling the appearance of stained real wood. Skin portions of doors and other structures have a surface layer of clear gel coat resin molded to include the texture of a wood grain surface. A subsurface layer adjacent the clear gel coat layer is of pigmented gel coat resin. A structural support layer of the skin is of reinforced resin. Skins of a door or similar article are mounted on frames, and dense micro porous resin foam is provided between the skins to form a solid structure such as a door. Moldings retaining glass panels in openings defined in the door or similar structure are attached to the skins by adhesively fastening the moldings to the skins. Fasteners mounted in the moldings so that there are no plugged holes in the exterior surfaces of the moldings are used to locate the moldings properly with respect to the skins by inserting the fasteners into predrilled holes in the skins.

Abstract: A method of forming a device including a plurality of micron or sub-micron sized features is provided. A master having a surface contour defining a plurality of features is provided. The surface contour of the master is coated with at least one layer of material to form a shell. The master is removed from the shell to form a negative image of the surface contour in the shell. The negative image in the shell is filled with material, for example, polycarbonate, polyacrylic, or polystyrene, to form a device having features substantially the same as the master. The negative image may be filled using injection molding, compression molding, embossing or any other compatible technique.

Abstract: A mold for molding a foamed tube for a tire is formed from a first mold and a second mold. Each mold has an annular concave portion for tube molding, and joining faces which are continuous with the annular concave portion and are formed at an inner side and an outer side, in a radial direction, of the annular concave portion. Each of the joining faces of the first mold and the joining faces of the second mold has horizontal joining faces provided adjacent to the annular concave portion in a direction orthogonal to an axial direction at a radially inner side and a radially outer side of the annular concave portion, and an inclined joining face provided continuously with the horizontal joining face so as to be inclined with respect to the horizontal joining face at one of an inner side and an outer side in the radial direction.

Abstract: An improved method of manufacturing a foam-molded product is provided including the steps of: filling a resin containing a foaming agent into a mold cavity by injection within a time period from a time point just before completion of mold clamping to a time point after the completion of mold clamping; allowing the resin thus filled in the mold cavity to form a skin layer over a surface thereof; thereafter retracting a movable mold to define a predetermined cavity clearance between the movable mold and a stationary mold, so as to cause the foaming agent contained in an uncured portion of the resin to foam; and cooling the resin filled in the cavity mold to form a foam-molded product having a surface forming a tight skin layer and an inside portion in a foamed state.

Abstract: A laminate structure for making a cushioned component for a vehicle interior, such as a seat cushion or head rest, has a high density foam bonded to an interior surface of a seat cover material. After the laminate structure is formed into a desired shape for the cushioned component, it is inserted into a vacuum mold having a mold surface with a shape corresponding with a desired exterior surface shape of the cushioned component. Liquid foam-forming material is injected into the laminate structure within the mold and allowed to cure to form the cushioned component. The high density foam of the laminate structure preferably has a density of at least 4 lbs/ft3 and an air permeability of 5 to 100 ft3/ft2 minute. This high density foam may be created by felting a polyurethane foam.

Abstract: An automotive headliner assembly includes a substrate that is configured to mount to a vehicle in a position generally covering a lower surface of a passenger compartment roof. Cavities are formed into the substrate between the upper substrate surface and the lower substrate surface to provide receptacles for electrical wiring, fiber optic cabling, EA foam and the like or to form a duct for directing air flow. Each of the cavities is integrally formed in the substrate. A foam layer is adhered to a lower surface of the substrate and the decorative cover is adhered to a lower surface of the foam layer. The headliner is constructed by first extruding molten parison into a blow mold shaped to complement the desired exterior contours of the headliner substrate to be formed. The cavities are then formed in the molten parison by inserting at least one blow pin into the parison and injecting pressurized gas.

Abstract: A method for making a shoe sole includes step of preparing various types of foamable material; step of making the foamable material into particles; step of preparing a mold having a cavity in which the foamable material is being put; and step of foaming the foamable material in the cavity and obtaining a sole. The foamable material has different resilient coefficients but the same foaming rate so that the sole can be a made by a single foaming process and includes various resilient features.

Abstract: Continuous polymeric extrusion nucleation systems and methods useful for making polymeric microcellular foamed materials, including crystalline and semi-crystalline polymeric microcellular materials, are provided. Pressure drop rate is an important feature in some embodiments, and the invention provides systems for controlling these and other parameters. One aspect involves a multiple-pathway nucleator that is separated from a shaping die by a residence chamber. Another aspect involves a die for making advantageously thick articles, including a multiple-pathway nucleation section. Microcellular material can be continuously extruded onto wire, resulting in a very thin, essentially closed-cell microcellular insulating coating secured to a wire. Other very thin microcellular products can be fabricated as well.

Abstract: A method for facilitating the fabrication of a hard cover for an article is provided. The method includes positioning shrinkable material over at least a portion of the article and shrinking the shrinkable material to form a fitted cover for the portion of the article. A layer of molding material is applied overlying the fitted cover to form a hard cover for the portion of the article. A method for facilitating fabrication of a first article from a second article is also provide. The method includes positioning shrinkable material over at least a portion of the second article and shrinking the shrinkable material to form a fitted cover for the portion of the second article. A first layer of molding material is applied overlying the fitted cover to form a mold. The mold has a surface which is a negative impression of at least a portion of the fitted cover. The mold is removed from the fitted cover and a second layer of molding material is applied overlying the surface of the mold to form the first article.

Abstract: In order to achieve an economical and trouble-free continuous extrusion of plastic hollow profiles having at least one hollow chamber that is filled with foam, the profile tool of an extrusion device is configured in the shape of a pistol. The profile tool comprises a pistol shaft (102) with a melt feed channel (166), connected to the melt discharge opening of the extruder (300) and which opens into a melt radial distributor channel (164) that surrounds the lance guide channel (150). The profile tool is also equipped with a pistol barrel (101) comprising a melt ring channel (162), which extends from the melt radial distributor channel (164) to the profile nozzle (160) and comprising a lance guide channel (150), which extends in a continuous manner from a lance inlet (152) to the profile nozzle (160).