Abstract: An apparatus and method of producing plastic articles comprising preheating a metal mold having a mold contour using infrared heating elements formed to match said mold contour to establish a casting temperature, casting plastic material onto the preheated metal mold surface, fusing the plastic using infrared energy, cooling the metal mold using the change of phase or state of a cooling material and removing the cast plastic article from said metal mold.

Abstract: An apparatus and method of producing plastic articles comprising preheating a metal mold (10) using infrared energy to establish a casting temperature, casting plastic material onto the preheated mold surface, fusing the plastic into a substantially uniform layer using infrared energy, cooling the metal mold using evaporative cooling, and removing the cast plastic article from said metal mold (10).

Abstract: A method for annealing a structure formed by electrodeposition is provided, the method comprising providing the electrodeposition structure, the electrodeposition structure comprising an electroformed mold, the electroformed mold having a nominal thickness between and including 0.5 mm to 8.0 mm and having a melting temperature; heating the electrodeposition structure to a temperature between ambient temperature and the melting temperature of the electrodeposition structure; isostatically pressurizing the electrodeposition structure to a pressure above ambient pressure; cooling the electrodeposition structure to ambient temperature; and depressurizing the electrodeposition structure to ambient pressure.

Abstract: A method for annealing a structure formed by electrodeposition is provided, the method comprising providing the electrodeposition structure, the electrodeposition structure comprising an electroformed mold, the electroformed mold having a nominal thickness between and including 0.5 mm to 8.0 mm and having a melting temperature; heating the electrodeposition structure to a temperature between ambient temperature and the melting temperature of the electrodeposition structure; isostatically pressurizing the electrodeposition structure to a pressure above ambient pressure; cooling the electrodeposition structure to ambient temperature; and depressurizing the electrodeposition structure to ambient pressure.

Abstract: A method for annealing a structure formed by electrodeposition including providing the electrodeposition structure, the electrodeposition structure including an eletroformed mold, the electroformed mold having a nominal thickness between and including 0.5 mm to 8.0 mm and having a melting temperature; heating the electrodeposition structure to a temperature between ambient temperature and the melting temperature of the electrodeposition structure; isostatically pressurizing the electrodeposition structure to a pressure above ambient pressure; cooling the electrodeposition structure to ambient temperature; and depressurizing the electrodeposition structure to ambient pressure.

Abstract: An apparatus and method of producing plastic articles comprising preheating a metal mold having a mold contour using infrared heating elements formed to match said mold contour to establish a casting temperature, casting plastic material onto the preheated metal mold surface, fusing the plastic using infrared energy, cooling the metal mold using the change of phase or state of a cooling material and removing the cast plastic article from said metal mold.

Abstract: An apparatus and method of producing plastic articles comprising preheating a metal mold (10) using infrared energy to establish a casting temperature, casting plastic material onto the preheated mold surface, fusing the plastic into a substantially uniform layer using infrared energy, cooling the metal mold using evaporative cooling, and removing the cast plastic article from said metal mold (10).

Abstract: A method for annealing a structure formed by electrodeposition is provided, the method comprising providing the electrodeposition structure, the electrodeposition structure comprising an electroformed mold, the electroformed mold having a nominal thickness between and including 0.5 mm to 8.0 mm and having a melting temperature; heating the electrodeposition structure to a temperature between ambient temperature and the melting temperature of the electrodeposition structure; isostatically pressurizing the electrodeposition structure to a pressure above ambient pressure; cooling the electrodeposition structure to ambient temperature; and depressurizing the electrodeposition structure to ambient pressure.

Abstract: Spherical particles having a diameter between 0.007″ and 0.040″ are formed from melt extruded thermo-plastic material suitable for casting on a heated mold surface and melting thereon to form a thin layer of material having a nominal thickness of 0.040″ that is cooled and removed from the mold surface as a part having a porosity less than a visually observable threshold. The process includes the steps of providing microspheres formed of blended and melt extruded thermo-plastic, plasticizers and pigment additives that constitute less than 5% by weight of the blend and shaped as a smooth round spherical particle; providing a heated casting surface and distributing a predetermined charge of such microspheres against the heated casting surface; melting the microspheres as a layer of thermoplastic material having a porosity less than 0.003 inches and thereafter cooling and removing the non-porous layer from the casting surface.

Abstract: Spherical particles having a diameter between 0.007" and 0.040" are formed from melt extruded thermoplastic material formed of blended and melt extruded thermoplastic and pigment.

Abstract: Sperhical particles having a diameter between 0.007" and 0.040" are formed from melt extruded thermoplastic material formed of blended and melt extruded thermoplastic and pigment.

Abstract: Spherical particles having a diameter between 0.007" and 0.040" are formed from melt extruded thermoplastic material suitable for casting on a heated mold surface and melting thereon to form a thin layer of material that is cooled and removed from the mold surface as a part having a porosity less than a visually observable threshold. The process includes the steps of providing microspheres formed of blended and melt extruded thermoplastic, plasticizers (if necessary) and pigment additives that constitute less than 5% by weight of the blend and shaped as a smooth round spherical particle. The microspheres may then be distributed as a predetermined charge of such microspheres against the heated casting surface to melt the microspheres as a layer of thermoplastic material having a porosity less than 0.003 inches and thereafter cooling and removing the non-porous layer from the casting surface.

Abstract: Spherical particles having a diameter between 0.007" and 0.040" are formed from melt extruded thermoplastic material suitable for casting on a heated mold surface and melting thereon to form a thin layer of material having a nominal thickness of 0.040" that is cooled and removed from the mold surface as a part having a porosity less than a visually observable threshold. The process includes the steps of providing microspheres formed of blended and melt extruded thermoplastic, plasticizers (if necessary) and pigment additives that constitute less than 5% by weight of the blend and shaped as a smooth round spherical particle. The microspheres may then be distributed as predetermined charge of such microspheres against the heated casting surface to melt the microspheres as a layer of thermoplastic material having a porosity less than 0.003 inches and thereafter cooling and removing the non-porous layer from the casting surface.

Abstract: An automotive interior trim component is constructed by placing a cast polyvinyl chloride (PVC), vacuum formed or sprayed thermoplastic/thermoset cover stock, or a cloth/fabric outer shell in a closeable mold, spraying a coating of urethane foam forming materials onto a back surface of the shell, closing the mold with a lid so that an insert is held in spaced relation to the shell and clamping the lid shut while the foam forming material react to provide a shaped foam cushion that is between and bonded to the shell and the insert.

Abstract: A method of producing a molded foam article having an integral skin and a backing layer of foam comprising mixing particles of two polyvinyl compounds one of the compounds having a molecular weight less than that of the other compound and a higher solvating plasticizer than that of the other compound and casting the mixture against a heated mold surface and melting the one compound to flood the interstices of the particles of the other compound and float to the surface of the heated mold to form a skin and wherein the other compound includes foaming constituents to simultaneously form a layer of foam material behind the skin.

Abstract: A method for recovering vinyl and urethane foam from composite plastic articles for recycling by granulating the article to form separated mixed components destaticizing the separate mixed components to prevent static during cling between foam particles and vinyl shell particles; and directing the destaticized particles through a vibrating fluidized bed to separate the vinyl shell particles and the foam particles.

Abstract: A method for testing foam formulations for the quantitative measure of the effects of formulation and/or process variable changes on some kinds of surface problems of a molded part caused by different degrees of imperfection or voiding underneath the part surface. The molded part can be single component or composite, solid or foamed. One example of the surface problem is the so-called "measles or cellulite" problem observed on the vinyl surface of a vinyl/foam composite due to the voids or rattiness within the foam. To accomplish this result, the mold has various sized, spaced apart, aligned openings formed in each of the front and rear walls of the mold, but with the centers thereof at different elevations in the respective front and rear walls. Removable rods inserted through the aligned mold wall openings produce longitudinal openings through the part which is molded around the rods, permitting the effect thereof on the surface of the molded part to be evaluated.

Abstract: A process of separating vinyl skin from a foam backing and recovering the separated components by granulating the plastics composite into small chips, mixing the chips with a quantity of water in a vessel to swell and break the cell structure of the foam at the foam/vinyl interface resulting in flotation of the foam bits and sinking of the heavier vinyl bits. The separated foam is recovered by adding additional water to flow the foam material from the mix vessel. The vinyl is then removed from the bottom of the vessel and the separated components are dried for recycling or improved disposal purposes.

Abstract: This disclosure illustrates and describes a test mold for the quantitative measure of the effects of formulation and/or process variable changes on some kinds of surface problems of a molded part caused by different degrees of imperfection or voiding underneath the part surface. The molded part can be single component or composite, solid or foamed. One example of the surface problem is the so-called "measles or cellulite" problem observed on the vinyl surface of a vinyl/foam composite due to the voids or rattiness within the foam. To accomplish this result, the mold has various sized, spaced apart, aligned openings formed in each of the front and rear walls of the mold, but with the centers thereof at different elevations in the respective front and rear walls. Removable rods inserted through the aligned mold wall openings produce longitudinal openings through the part which is molded around the rods, permitting the effect thereof on the surface of the molded part to be evaluated.

Abstract: A process for molding plastic parts includes the steps of providing two or more colors of pigmented powder particles of thermoplastic material; casting the particles against a heated surface to form non-patterned layers of particles with voids therebetween; heating the layers to form color blended fused fringe zones between the particles which fill the voids to form a solid, multi-colored, three-dimensional article while each particle retains its discrete particle core which maintains each particle's central or original color concentration and which cores have discernible light transmissive properties.