Abstract: The elements of a tire pressure monitoring and transmitting system are encapsulated into a single package. A pressure sensitive device is covered with a flexible gel coat and then inserted into a molding tool cavity. A removable pin is incorporated into the molding tool and in its normal position is in contact with the gel. A molding compound is injected into the cavity so as to encapsulate the device and gel coat. When the pin is extracted and the device ejected from the molding cavity, an airway is left defined by the removable pin. The airway exposes the flexible gel covering the pressure sensitive device to the local air pressure, whereby the gel, being flexible, transfers the pressure to the pressure sensitive device.

Abstract: A process for producing an article in a flexible foamed polymer material, including treating a former with a coagulant; dipping the treated former in a latex foam mixture to form a layer of the mixture on the former that includes air cells; curing the layer to gel the foam mixture to a cross-linked open cell structure; and stripping the layer from the former; where the latex foam mixture includes a natural latex polymer as a primary polymer component, and a synthetic latex polymer as a secondary polymer component, which synthetic latex polymer is selected to enhance the evenness and/or fineness of said open cell structure.

Abstract: The present invention is directed to a method of preparing an article of manufacture. The method includes bringing at least a portion of a heated thermoplastic sheet into contact with at least a portion of the first surface of a support having a plurality of perforations. A vacuum is formed on the second surface of the support, and portions the heated thermoplastic sheet are drawn through the perforations of the support and to the second surface side of the support. Thermoplastic attachment heads are formed on the second surface side of the support, from the thermoplastic material of the sheet that is drawn through the perforations. The thermoplastic sheet and the support are fixedly attached one to the other by means of the edges of the perforations being embedded in the thermoplastic material of the sheet drawn therethrough, and the thermoplastic attachment heads. Also disclosed are articles of manufacture, such as interior and exterior automotive body panels and components.

Abstract: A method of insert molding a preformed item into a molded product, the molded product being formed by injecting a moldable material into a mold, is disclosed. The method includes adhering the preformed item to a surface of the mold with an adhesive, wherein the surface to which the preformed item is adhered is free of any features provided for holding the preformed item in place on the mold surface. The method next includes injecting the moldable material into the mold such that the moldable material at least partially surrounds the preformed item, and curing the moldable material. Articles molded via the disclosed method are also described.

Abstract: A method of manufacturing a molded product comprising the steps of: providing a mold conforming to the shape of the product the mold serving to define one or more molding surfaces which are to be reproduced in an article formed via the mold; mounting in the mold an article including or forming an image comprising at least one device, logo, letter, word or words or combinations of these in such a way that most, if not all of the article lies within the mold out of contact with the or each molding surface; and injecting into the mold a supply of polymerisible material so as to immerse the article; the material, at least following polymerisation being flexible and so providing at least in part, a substantially transparent product; and withdrawing the product from the mold. Typically the step of providing product is directed to an article of footwear such as a shoe or swimming fin (also known as a flipper).

Abstract: The present invention relates to a method and installation for integrally applying a relief decoration to the surface of solid elongate members. The installation comprises a pre-heater (43) with pre-heater control means (69), a press (51), and a camber measurement system (67). The pre-heater (43) is adapted for differently heating the surface of two opposing faces of an elongate member previous to feeding it to the press (51) for applying the relief decoration. The camber measurement system (67) measures possible camber of the elongate member coming out of the press (51) and generates camber measurement signals which are fed back to the pre-heater control means (69) for controlling the heating of the pre-heater (43). The aim of the installation of the present invention is to eliminate the camber of following elongate members to which a relief decoration is to be applied.

Abstract: A composite pole including a structural member and a cured resin layer adjacent the structural member and defining an exterior surface. The composite pole can be manufactured by providing a mold, inserting a structural member within the mold to define a space between the structural member and the mold, filling the space between the structural member and the mold with a liquid thermosetting resin, curing the liquid thermosetting resin to define an exterior surface, and removing the cured liquid thermosetting resin and structural member from the mold. The composite pole can also be manufactured by casting a jacket onto an installed pole by applying a mold around the installed pole, filling a space between the installed pole and the mold with a liquid thermosetting resin, curing the liquid thermosetting resin to define an exterior surface, and removing the mold from around the cured liquid thermosetting resin and the installed pole.

Abstract: A resin part of a vehicular lamp and a method for producing such a part in which a metallic vapor deposition coating for forming a reflective surface is formed directly on a surface of a resin body part without applying an undercoating layer. The body of the resin part is produced by injecting molten resin into a cavity of a molding die in which a heat insulating layer is formed on a portion of the cavity surface corresponding to the reflective surface. A metallic vapor deposition coating is applied directly to the portions of the body of the resin part which were in contact with the heat insulating layer during injection molding.

Abstract: A mold tool includes upper and lower sections defining a cavity within which a plastic film preform is placed before injection of plastic forming a molded article. The plastic film extends between an interface defined between the sections of the mold. The interface secures a position of the plastic film within the mold tool preventing movement during injection of plastic. The interface is specifically configured to secure the plastic film without damage. The specific configuration of the interface is determined according to a relationship between molding process parameters and physical characteristics of the plastic film.

Abstract: A resin sealing mold for semiconductor devices, which is designed to thoroughly accommodate board thickness variations and prevent formation of burrs and which is easy to maintain. To this end, a plurality of pistons (42) supporting, at one of their respective ends, lower mold cavities (56) have the other ends thereof slidably inserted in hydraulic cylinder blocks installed on lower mold sets (40).

Abstract: A method for fabricating a seal-integrated separator for a fuel cell is presented, with which seals can be accurately positioned and the assembling time for the fuel cell units may be greatly reduced.

Abstract: The mold for a thin package uses a gate which has a high aspect ratio, about 30 degrees or greater throughout the length of the gate. Additionally, the depth of the gate goes to zero at a point outside of the area of the finished package, but within the dam bars, so that the leadframe space acts as a virtual gate. This reduces the need for trimming and lowers stress on the finished package.

Abstract: An interior trim component is formed utilizing an injection molding apparatus having first and second molds. The component includes a laminate and a polymer. The laminate includes a face layer having a finished and unfinished side, an adhesive layer bonded to the unfinished side, and a barrier bonded to the adhesive layer. The barrier includes a non-woven textile weighing at least 80 g/m2. The laminate is positioned in the first mold such that the barrier is exposed to face the second mold. The apparatus is moved into a closed position and a cavity is established between the barrier and the second mold. The polymer is injected into the cavity at a pressure of at least 500 psi. The polymer reacts with the barrier to bond the laminate to the polymer and to form the interior trim component without the polymer penetrating through the barrier and into the face layer.

Abstract: In the production of a vulcanized rubber-resin composite material by providing a vulcanized rubber molding in a mold, followed by injecting a resin into the mold, a vulcanizable adhesive layer containing brominated poly(2,3-dichlorobutadiene-1,3) as the main component is formed on the surface to be bonded of the vulcanized rubber molding, and then injecting the resin while keeping the vulcanizable adhesive layer to stay as formed on the surface to be bonded, thereby effecting the bonding, where a strong adhesion is established between the vulcanized rubber molding and the resin layer without any heat treatment of the vulcanized rubber molding before provision of the vulcanized rubber molding in the mold or without any heat treatment of the composite material after the resin injection.

Abstract: A method and apparatus for molding a right angle connector onto a tube end portion. The tube end portion is positioned in a mold cavity; an axially extending core is positioned in the mold cavity with the axis of the core at a right angle to the axis of the tube end portion and with an inboard end of the core positioned proximate the open end of the tube end portion; a molten plastic material is injected into the mold cavity in surrounding relation to the core and the tube end portion; and the core is removed to form a connector fixedly secured to the tube end portion and having a central axial bore communicating with the open end of the tube, extending at a right angle to the central axis of the tube end portion, and conforming to the configuration of the core.

Abstract: A mold for producing a finished countertop on top of a countertop substrate is provided. The mold is comprised of a shaped inner surface to receive a countertop material pour and form a countertop edge and a tab extending from the shaped inner surface, the tab dimensioned to cover at least part of the substrate edge and extend over at least a part of the substrate top and hold the shaped inner surface adjacent the countertop substrate edge. Also included in the invention is a method of making a countertop using the mold.

Abstract: A mold tool (16) for forming a trim covered foam substrate of a seat assembly comprises an upper mold cast (18) defining an upper mold surface (19) and a lower mold cast (20) defining a lower mold surface (2). A split line (28) is defined adjacent to the upper and lower mold surfaces between the upper mold cast and the lower mold cast when the mold casts are in facing mating engagement forming a mold cavity (22) therebetween. A plurality of heat lines (24) extend through the upper (18) and lower (19) mold casts adjacent the respective upper and lower mold surfaces for heating the mold cavity (22). A cooling line (30) extends through at least one of the upper and lower mold casts adjacent the split line (28) for cooling the split line of the mold tool.

Abstract: Techniques for forming packaged semiconductor devices having top surfaces with flash-free electrical contact surfaces are described. According to one aspect, a molding cavity is provided which has a molding surface that is sufficiently smooth such that when placed in contact with an electrically conductive contact, gaps between the conductive contact and the mold cavity surface do not form.

Abstract: The upper and lower mold plates of a transfer molding machine are configured for one-side encapsulation of a pair of substrate mounted electronic devices having an opposite conductor-grid-array and/or bare heat sink/dissipater. A buffer member, optionally with cut-outs or apertures, may be placed between the two back-to-back substrates for protecting the grid-arrays and enabling encapsulation of devices with varying thicknesses without adjustment of the molding machine. Alternately, the upper and lower plates are configured for one-side encasement using covers of a pair of substrate mounted electronic devices having an opposite conductor-grid-array and/or bare heat sink/dissipater.

Abstract: A method of manufacturing a super-thin advertising and decorative zipper tab, comprising the following steps: 1) casting the first mold with one end of a soft string disposed therein; 2) providing a sprue on the first mold at a position under the soft string before closing the first mold and injecting plastic to conjunct the soft string within the first molding blank; and 3) placing the molding blank into a second mold such that a sprue is provided at a position above the soft string before closing the second mold and injecting plastic to conjunct half of the second molding blank with the soft string, in order to manufacture a super-thin advertising and decorative tab.