Abstract: A method for forming an angled plastic article of varying density whereby a blowing agent is added to a plastic material and the material is injected into a mold cavity of a mold unit. The interior walls of the mold cavity are maintained at a temperature sufficient to prevent the outer skin of the hardening plastic article from producing gas bubbles. The volume of the mold cavity is increased to allow bubbles to produce and uniformly distribute themselves throughout the mold cavity and then a reconversion phase is instituted whereby the desired density of the finished plastic article is achieved without voids or aberrations appearing in the surface of the plastic article. The mold unit is provided with extensible beveled edges which extend and retract as the mold cavity is enlarged and compressed. By this method, a resulting plastic article of varying density is produced having grooves running the length of the article.

Abstract: A heat laminated fabric hinge and a method of making same, where the heat laminated fabric hinge comprises a first member with a hinge attachment surface, a second member with a hinge attachment surface, and a fabric hinge member. The fabric hinge member is secured to the hinge attachment surfaces of the first and the second members by heat lamination, whereby at least some of the fibers of the fabric hinge member are embedded within the hinge attachment surfaces of the first and the second members.

Abstract: A method for producing an injection molded article with a gradually varying cellular density distribution, whereby the cellular density distribution varies between a first cellular structure of a high density and a second cellular structure of a relatively lower density. The method comprises forming a mold cavity be engaging a first mold section with a second mold section and injecting into the mold cavity an injection mixture which contains a blowing agent. A gradually varying density distribution is created according to a predetermined control function which depends on the mold cavity volume and the injection rate of the injection mixture.

Abstract: An injection molded bottle closure with a gradually varying cellular density distribution, whereby the cellular density distribution varies between a first cellular structure of a high density and a second cellular structure of a relatively lower density. The method of forming the injection molded bottle closure comprises forming a mold cavity be engaging a first mold section with a second mold section having a retractable portion, and injecting into the mold cavity an injection mixture which contains a blowing agent. A gradually varying density distribution is created according to a predetermined control function which depends on the mold cavity volume and the injection rate of the injection mixture.

Abstract: A method of molding a plastic with a foamed interior and a dense outer skin of a desired thickness, whereby a blowing agent is mixed with a plastic material and the mixture is injected, under pressure, into a mold cavity of a mold unit. The mixture is allowed to cool along the molding surfaces of the mold cavity for a determined amount of time. The pressure is released and the mold cavity expanded to allow the blowing agent to foam the interior of the plastic article. The molding cavity is then compressed to achieve the desired dimensions for the plastic article, and to give the interior a uniform cellular structure. Control over the timing of the expansion of the mold cavity, the injection temperature, the rate of injection of the mixture, the rate at which the cavity is expanded and compressed, and the timing of the compression of the mold cavity allow a skin of desired thickness to be formed on the plastic article.

Abstract: A method of making a multiple-layer article having a surface application material effectively bonded to an injection molded plastic member is provided along with a method for making same. At least a portion of an intermediary substratum is located inside a mold cavity during injection of a plastic injection material where the plastic injection material contacts and becomes partially absorbed into a first side of the intermediary substratum. The plastic member and the intermediary substratum are then removed from the mold cavity, and the surface application material is applied to a second side of the intermediary substratum where the surface application material becomes partially absorbed into the second side of the intermediary substratum.

Abstract: A method for injecting a plastic material into a mold cavity to precisely fill the mold cavity under low pressure and to avoid packing the mold cavity with plastic material. The plastic material is injected into the mold cavity at a rate sufficient to maintain an unbroken melt front and to avoid any spraying or splashing of the plastic material within the mold cavity. After an initial unbroken melt front is established, the rate at which the material is injected is increased in proportion to the size of the melt front. After a predetermined amount of the material has entered the mold cavity, the material is injected based upon a rate-dominated control algorithm which maintains the unbroken melt front. Once the mold cavity has reached a pre-determined level of fill, the rate-dominated control algorithm is changed to a pressure-dominated control algorithm to prevent overrunning the end point of the mold process and to eliminate splashing and associated backflow problems.

Abstract: A method for injecting a plastic material into a mold cavity to precisely fill the mold cavity under low pressure and to avoid packing the mold cavity with plastic material. The plastic material is injected into the mold cavity at a rate sufficient to maintain an unbroken melt front and to avoid any spraying or splashing of the plastic material within the mold cavity. After an initial unbroken melt front is established, the rate at which the material is injected is increased in proportion to the size of the melt front. After a predetermined amount of the material has entered the mold cavity, the material is injected based upon a rate-dominated control algorithm which maintains the unbroken melt front.

Abstract: A method for forming an angled plastic article of varying density whereby a blowing agent is added to a plastic material and the material is injected into a mold cavity of a mold unit. The interior walls of the mold cavity are maintained at a temperature sufficient to prevent the outer skin of the hardening plastic article from producing gas bubbles. The volume of the mold cavity is increased to allow bubbles to produce and uniformly distribute themselves throughout the mold cavity and then a reconversion phase is instituted whereby the desired density of the finished plastic article is achieved without voids or aberrations appearing in the surface of the plastic article. The mold unit is provided with extensible beveled edges which extend and retract as the mold cavity is enlarged and compressed. By this method, a resulting plastic article of varying density is produced having grooves running the length of the article.

Abstract: A plastic article and method of molding same is provided where the plastic article includes a plastic member having a first ridge and a second ridge. The plastic member is partially absorbed into and is in bonded engagement with at least a portion of a first laminate and the first laminate has an edge imbedded in the first ridge of the plastic member. Also, the plastic member is partially absorbed into and is in bonded engagement with at least a portion of a second laminate and the second laminate has a first edge imbedded in the first ridge of the plastic member and a second edge imbedded in the second ridge of the plastic member. The plastic member is also partially absorbed into and is in bonded engagement with at least a portion of a third laminate and the third laminate has an edge imbedded in the second ridge of the plastic member.

Abstract: An extruded-in fabric hinge comprised of a fabric hinge member extruded-in with a first member and a second member such that at least some of the fibers of the fabric hinge member are embedded within the first and second members. An extruder apparatus with an extrusion cavity comprised of a first surface with a first adjustable mandrel, a second surface, a third surface, and a fourth surface integrated to form the extrusion cavity is used to make the extruded-in fabric hinge. A fabric hinge member is captured between the first adjustable mandrel and the second surface, and an extrusion material is extruded through an extrusion inlet of the extruder apparatus and into the extrusion cavity. The extrusion material integrates with the fabric hinge member such that at least some of the fibers of the fabric hinge member are embedded into the first and second members of the extruded-in fabric hinge.

Abstract: A method for injecting a plastic material into a mold cavity to precisely fill the mold cavity under low pressure and to avoid packing the mold cavity with plastic material. The plastic material is injected into the mold cavity at a rate sufficient to maintain an unbroken melt front and to avoid any spraying or splashing of the plastic material within the mold cavity. After an initial unbroken melt front is established, the rate at which the material is injected is increased in proportion to the size of the melt front. After a predetermined amount of the material has entered the mold cavity, the material is injected based upon a rate-dominated control algorithm which maintains the unbroken melt front.

Abstract: An article of manufacture is provided where the article of manufacture comprises a computer usable medium having computer readable program code means therein. The computer readable program code means causes a computer to receive information, establish a molding profile based on the information, operate a molding machine to mold an article according to the molding profile, receive additional information corresponding to detected irregularities on the molded article, establish a modified molding profile based on the additional information received, and operate the molding machine to mold an additional article according to the modified molding profile. The additional information received by the computer which corresponds to detected irregularities on the molded article may be provided by a human operator, by a second computer, or by any other means.

Abstract: A method for injecting a plastic material into a mold cavity to precisely fill the mold cavity under low pressure and to avoid packing the mold cavity with plastic material. The plastic material is injected into the mold cavity at a rate sufficient to maintain an unbroken melt front and to avoid any spraying or splashing of the plastic material within the mold cavity. After an initial unbroken melt front is established, the rate at which the material is injected is increased in proportion to the size of the melt front. After a predetermined amount of the material has entered the mold cavity, the material is injected based upon a rate-dominated control algorithm which maintains the unbroken melt front. Once the mold cavity has reached a pre-determined level of fill, the rate-dominated control algorithm is changed to a pressure-dominated control algorithm to prevent overrunning the end point of the mold process and to eliminate splashing and associated backflow problems.

Abstract: A seat unit is provided comprising a base structure and at least one cushion layer comprised of a random mesh of plastic filament between the base structure and the cover layer. The cushion layer not only provides adequate firmness, but has adequate air circulation therethrough. The perimeter of the cushion may be molded in with a plastic base structure, and there may be multiple cushion layers where each layer has a different density. The multiple layers of cushioning where each layer has a different density further allow the seat to have both a specifically desired firmness and air circulation therethrough. Also provided is a method for molding in the cushioning with the base structure as well as molding in a spring layer and a cover layer.

Abstract: An apparatus and method for sequentially molding a plurality of plastic articles within a single mold unit. A first mold section is provided with a runner system and a plurality of gates and a second mold section is provided with a plurality of recesses in operable alignment with the gates of the first mold section. When the second mold section is clamped into mating engagement with the first mold section, a plurality of discrete mold cavities are formed, each having at least one corresponding gate provided on the first mold section. A central processing unit signals an injection assembly as to the proper injection parameters for each discrete mold cavity. The central processing unit opens the gates sequentially, with each discrete mold cavity being filled according to its own set of injection parameters. By the present method, it is possible to mold a plurality of articles having different injection parameters, while using a single mold unit.

Abstract: A process for making a hinged plastic article wherein a hinge formed from a deformable lamina is integrated with first and second thermoplastic members during injection of the plastic material. The deformable lamina is placed between the first mold section and the second mold section of an injection mold unit before the first mold section and the second mold section are clamped together to form injection mold cavities for the first and second thermoplastic members. A mold cavity dividing member separates the mold cavities for the first and second thermoplastic members. The deformable lamina at least partially extends into the mold cavity for the first thermoplastic member and the mold cavity for the second thermoplastic member as well as therebetween to form a hinge. The first mold section and the second mold section are then clamped together and a plastic material is injected into the mold cavities and in bonding securement of the deformable lamina.

Abstract: A metal reinforced plastic article is provided and comprises a first plastic member and a second plastic member bonded together through a plurality of apertures in a metal reinforcing member. Preferably, the metal reinforcing member has a plurality of angled protrusions on a first and second side. The protrusions on the first side are pressed into the first plastic member and the first plastic member is bonded to the protrusions, and the protrusions on the second side are pressed into the second plastic member and the second plastic member is bonded to the protrusions.A method of forming a metal reinforced plastic article is provided and comprises providing a first plastic member and a second plastic member. A metal reinforcing member having a plurality of apertures therein, and having a plurality of angled protrusions on a first and second side is provided.

Abstract: A method and apparatus for clamping a plastic injection mold. The apparatus utilizes leader pins connected directly to a pair of mold sections. By directly connecting the leader pins to the mold sections, standard platens and housings can be eliminated, thereby reducing the overall weight and dimensions of the apparatus. An ejection assembly and runner assembly are bolted onto the mold sections, but are not subjected to clamping pressures during the molding process. Since these assemblies are not subject to clamping pressures, the standard housings usually provided on these assemblies may also be eliminated.

Abstract: An apparatus and method for clamping a plastic injection mold. A first mold section is provided with a plurality of leader pins which protrude through apertures in a second mold section when the mold sections are brought into mating engagement to form a mold cavity. The second mold section is provided with cylindrical hydraulic cylinders having longitudinal passageways sufficient to accommodate the leader pins. Each hydraulic cylinder is provided with a locking assembly capable of engaging grooves provided in the ends of the leader pins. Once the leader pins have been moved through the second mold section and hydraulic cylinders the locking mechanisms engage the leader pins to allow the hydraulic cylinders to push against the locking mechanisms in an effort to clamp the mold sections together. By using a plurality of strategically placed leader pins and clamping assemblies, large clamping systems can be eliminated and more precise clamping pressures can be applied to the mold sections.