Abstract: Cores for manufacture of molded products are fabricated from ceramic microspheres in combination with 5-20% polymer binder in water solution, the binder comprising poly(2-ethyl-2-oxazoline) and polyvinylpyrrolidone.

Abstract: In order to reduce the throughput times of a manufacturing process and the space required for the manufacturing facilities for a plastic injection molding that is laminated with a textile fabric, a non-woven or the like, particularly a piece of interior trim for an automobile, a process is provided comprising the following steps: loading of a fabric blank, which is coated on a first side facing the injection molding with a plastic film that is thermoformable and, when cooled, dimensionally stable and elastic; preforming the fabric blank into the desired outer contour of the injection molding to be manufactured; inserting the preformed fabric blank into the injection mold; injection-backing the fabric blank with plastic; and ejecting the laminated injection molding.

Abstract: The invention provides a printing ink less susceptible to decoration rolling in association with a decorated film or sheet used for integral injection molding. The ink of the present invention is used for printing of a decorated film or sheet integrated with a synthetic resin melt at a synthetic resin molding step to apply a decoration on a molded article simultaneously with molding, and comprises a binder comprising a polycarbonate resin, and a metal particle coated on the surface thereof with a coupling agent or a synthetic resin.

Abstract: A transducer backing material includes a sticky epoxy resin containing tungsten particles and silver particles. A method of applying a backing material to a transducer includes pouring a mixture of epoxy resin, tungsten particles, and silver particles into a mold containing a layer of piezoelectric material, degassing the mixture, and curing the mixture at a pressure of approximately one atmosphere until the mixture dries.

Abstract: A photocurable prepreg sheet for waterproofing includes (1) a fiber-reinforced resin layer which comprises a sheet-shaped inorganic or organic fibrous reinforcing material impregnated with a resin composition comprising: (A) an unsaturated polyester resin and/or vinyl ester resin: 100 parts by weight, and (B) at least two photopolymerization initiators having photosensitivity in different wavelength ranges from ultraviolet range to near infrared range: 0.01 to 10 parts by weight, and which is treated with light of a specific wavelength to thereby undergo prepolymerization which causes at least one of the polymerization initiators and radical-polymerizable unsaturated groups to remain partially intact; and (2) film which covers an upper surface and a back surface of the fiber-reinforced resin layer.

Abstract: A corrugated fuel tube is manufactured by extruding an inner single layer or multilayer of a resin of high fuel impermeability, extruding an outer single layer or multilayer of a thermoplastic resin so as to cover the inner layer to form a tube having a multi-layered wall, and corrugating the tube along at least a part thereof. The surface treatment is preferably given to an outer peripheral surface of the inner layer to ensure an improved adhesion between the inner and outer layers. The tube can be made without presenting any problem caused by a difference in melt viscosity between the materials forming its inner and outer layers.

Abstract: Methods for preparing a panel unit having a panel and a frame in which a first molding piece is formed by engaging an extrusion port of an extrusion molding die with a peripheral edge of the panel and extruding an extruded molding material along the peripheral edge of the panel. The extruded molding material preferably simultaneously bonds to the peripheral edge. Waste pieces may be eliminated from the first molding piece after bonding the first molding piece to the peripheral edge and the frame may be completed by adding an additional molding piece to provide a continuously formed frame around the peripheral edge. The first molding piece may be formed by continuously moving the peripheral edge relative to the extrusion port in a predetermined orbital path. The peripheral edge of the panel may be subjected to a primer treatment before engaging the extrusion port.

Abstract: A method of manufacturing golf balls is disclosed that prevents the cover from cracking due to thermal expansion of the core during the cover formation process. The method includes the forming a core. One or more optional boundary layers can be applied to the surface of the core. The core and any boundary layers are pre-heated such that the core and any boundary layer undergo volumetric thermal expansion. After the pre-heating, the cover of the ball is formed over the core and any boundary layer. The method of the present invention also decreases cover molding cycle times for golf balls.

Abstract: A method for making insulated pre-formed wall panels for attachment to like insulated pre-formed wall panels for building a wall. The method includes providing a mold for casting a concrete body having a generally planar portion with a plurality of rib portions extending therefrom, nesting at least one insulation strip within a respective spring member, covering the end portions of the respective spring member with a thermally insulating material to limit thermal conductivity from each respective rib portion of the concrete body to each respective spring member, inserting each respective spring member with the at least one nested insulation strip in the mold, and casting the concrete body in the mold with each respective spring member with the at least one insulation strip being unitarily attached to an edge portion of each respective rib portion with the end portion of each respective spring member being anchored in each respective rib portion of the concrete body to make the insulated pre-formed wall panel.

Abstract: There is provided a structure of a high quality appearance formed by adhesion of a substrate of a polyolefin resin with a film of an acrylic resin at the back side thereof with use of an adhesive agent, the film being formed by an extrusion molding method and a surface of the film being not lower than 80% in a 60° specular glossiness, which satisfies all properties of surface glossiness, scratch resistance, transparency and weatherability at the same time.

Abstract: A system and method are disclosed for molding a part, such as a point-of-purchase display, is shown. The system comprises a plasticator and press. The molded part comprises an in-molded graphics sheet which becomes molded integral with the part.

Abstract: A prefabricated insulated wall panel for building a wall. The wall panel includes one or more outer planar portions, a plurality of rib portions integral therewith and normal thereto and between which insulation is received, a strip of insulation attached to the inner edge of each rib portion for reducing thermal conductivity from the respective rib portion to wallboard attached to the wall panel, and a wallboard nailer strip which extends about the sides of the strip of insulation and has edge portions which are anchored in the respective rib portion. In accordance with one aspect of the invention, the nailer edge portions are insulated from the respective rib portion to limit thermal conductivity from the respective rib portion to the nailer. In accordance with another aspect of the invention, a pair of planar portions extend at an angle relative to each other so that the panel serves as a corner wall panel.

Abstract: A composite fabric for use in reinforcement, particularly tensile reinforcement, of cementitious boards and similar prefabricated building wall panels. The fabric is constructed as a mesh of continuously coated, high modulus of elasticity strands. The high modulus strands are preferably bundled glass fibers encapsulated by alkali and water resistant thermoplastic material. The composite fabric also has suitable physical characteristics for embedment within the cement matrix of the panels or boards closely adjacent the opposed faces thereof. The fabric provides long-lasting, high strength tensile reinforcement of the panels or boards regardless of their spatial orientation during handling. The reinforcement also enhances the impact resistance of the boards after installation. Included as part of the invention are methods for making the reinforcement, cementitious boards and panels including the reinforcement, and methods for manufacturing such boards and panels.

Abstract: A method forms a plastic package (28) for a sensing die (10) having a pressure sensitive diaphragm (22), wherein the diaphragm (22) has a first surface (24) and a second surface (26) disposed opposite the first surface (24). According to this method, the sensing die (10) is mounted overlying a hole (18) in a die bond pad (16), which is used to support the sensing die (10) in the package (28). Next, the sensing die (10) is enclosed within a mold (12,14), and a molding material is introduced into the mold's interior to form the package (28) around the sensing die (10). During molding, the pressures on the first and second surfaces (24,26) of the diaphragm (22) are sufficiently equal to substantially prevent damage to the sensing die (10).

Abstract: The present invention provides a transfer material and surface protecting sheet which can provide a molded article excellent in abrasion resistance and chemical resistance without causing crack in curved part of the molded article. The present invention can make possible not to remain fluidity and stickiness on a protecting printed layer prior to irradiation with an active energy ray, even in an inline printing process. A transfer material or a surface protecting sheet of the present invention has, a substrate sheet, a protecting printed layer which consists of an active energy ray curable resin composition comprising a polyaddition reaction product having an urethane bond amount of from 6000 to 50000 g/eq as an effective ingredient on a surface of the substrate sheet, and an additional printed layer on the protecting printed layer or on the opposite surface of the substrate sheet.

Abstract: A panel unit comprising a window glass panel, and a frame continuously formed on a peripheral edge of the window glass panel by extrusion molding and simultaneously bonded to the peripheral edge of said window glass panel. The frame is formed on the peripheral edge of the window glass panel so as to cover a part of the upper and lower surfaces and the end surface of the window glass panel.

Abstract: This steering wheel includes a ring portion to be gripped during steering, a core, a core coating layer coating the core and having a surface, and a decorative layer arranged at one or more surface portions of the core coating layer. The decorative layer has a printed layer and a transparent protective coating layer protecting the printed layer. The steering wheel is made by a process in which the core coating layer is molded around the ring portion in a mold, the printed layer is formed on the surface portions of the core coating layer by hydraulic transfer, and the protective coating layer is formed by applying a coating agent to a surface of the printed layer.

Abstract: A panel unit comprising a window glass panel, and a frame continuously formed on a peripheral edge of the window glass panel by extrusion molding and simultaneously bonded to the peripheral edge of said window glass panel. The frame is formed on the peripheral edge of the window glass panel so as to cover a part of the upper and lower surfaces and the end surface of the window glass panel.

Abstract: A novel construction board composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state for use in a construction board composition comprising primarily gypsum, and in a construction board composition comprising an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum construction board formulations, thus reducing the weight while maintaining the strength of the construction board structure. In a preferred embodiment, the lightweight, strengthened gypsum construction board of the present invention also comprises an optional covering veneer that is applied to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength.

Abstract: The present invention provides a process and apparatus for manufacturing an electromagnetic interference shielding metallic foil cladded plastic product.

Abstract: A method for bonding a tube into a device each of which is formed from a thermoplastic polymer. The device has first and second solid members in spaced apart relationship to form a hollow cavity therebetween. At least one linear channel extends through each of said solid members in an aligned relationship, such that a tube may be passed through in sliding engagement, including through the hollow cavity. Molten polymeric composition is injected into the hollow cavity at a temperature lower than the melting point of the thermoplastic polymer so as to bond to the thermoplastic polymer and to the tube to form fluid-tight bonds therewith.

Abstract: A thermoplastic and thermoformable pigment-containing metallic automotive paint is solvent cast and dried to form a finished metallic automotive paint coat for a decorative film used in a thermoforming process to form an exterior paint layer on a molded plastic automotive body panel. The paint coat contains a pigment uniformly dispersed in a polymeric binder material preferably comprising an alloy of a polyvinylidene fluoride (PVDF) copolymer and an acrylic resin in which the PVDF copolymer is provided as a dispersion in the acrylic resin. Preferably, the dispersed form of the PVDF copolymer has a particle size of about eleven microns or less, and more preferably a mean particle size range of about 3 to about 4.5 microns. The dispersion ratio is preferably from 80% to 20% PVDF copolymer and from 20% to 80% acrylic resin, respectively, by a weight. A low molecular weight form of the PVDF copolymer is preferred and characterized by a melt viscosity of 17,000 to 20,000 poise at 230.degree. C.

Abstract: The invention comprises devices composed of at least one microscopic hollow tube having a wall of single or multiple layers with a thickness of at st one nanometer and a diameter of at least 5 nanometers. The walls of the tubes can be formed from a wide variety of materials, some of the preferred materials include metals, polymers, carbon, ceramics, glasses. If the space between the tubes is filled, the tubes become channels in a monolithic or composite body. The channels can have a random or ordered orientation. The interior of the tube walls can be coated with a desired material such as a catalyst and also may have depressions or elevations therein that were imparted to the fibers upon which the tubes are formed. The wall layers may be porous for the purpose of removing the fiber therethrough. Microtubes and microtube devices may be interfaced with the macroscopic world in a number of ways.

Abstract: A urethane hammer or other hand-held striking tool having a handle portion cast of a lower durometer, more flexible grade of urethane material, and a head portion which is cast around a metallic weight at the end of the handle portion. The flexible handle absorbs shocks, while the hard material of the head provides a durable, effective striking surface. The tool is cast using a two-stage process. In the first stage, the handle portion is cast with the metal weight located in its end. The handle portion is then placed in a second mold in which the weight on the end of the handle extends into a larger cavity corresponding to the head portion of the tool. The higher durometer urethane material is then cast in this cavity so as to encase the weight and the end of the handle portion.

Abstract: A method for producing a sealing member for a battery includes integrally insert-molding a gasket on a peripheral edge of a metal sealing plate. The gasket is molded on the peripheral edge of the metal sealing plate by inserting the metal sealing plate between the female and male molds, the female mold having a concave surface conforming to the upper surface of the metal sealing plate and provided with a magnet or vacuum suction mouth to attract the metal sealing plate in its center, and the male mold having a surface conforming to the lower surface of the metal sealing plate, then injecting a molten resin into a cavity formed between the female mold and the male mold while pressing the female and male molds against each other by an elastic member.

Abstract: The fascia of a vehicle heating control panel is obtained by overmolding onto a monolayer flat film made of polycarbonate, elements made of different thermoplastic materials so as to allow marks and/or symbols formed by silkscreen printing on the film and present on a rotary knob to be illuminated by a transparency, while at the same time preventing the leaking of light.

Abstract: An intravascular catheter system and method of manufacture for implanting a radially expandable stent within a body vessel. The catheter system includes a shaft defining an inflation lumen in fluid communication with a balloon on the distal end of the shaft. A stent is mounted coaxially upon a balloon. The balloon has ridges impressed in the outline of the stent for at least a portion of the stent. The ridges are sized to receive the stent so as to cause the balloon to expand evenly and the stent to deploy uniformly. In an alternative embodiment the balloon may additionally have a polymeric surface layer exhibiting a higher coefficient of friction than the underlying material against the stent material. The surface layer may be provided as a high friction polymeric coating on a formed balloon or as a coaxial extrusion of a high friction polymeric material over the underlying balloon tubing material.

Abstract: A method of making a golf ball having a core and outer polyurethane cover by placing a first portion of polyurethane in a first cavity and allowing the first portion of polyurethane to partially cure to a selected state of gel. The core is positioned within the cavity while the core is vertically and laterally centered within the cavity. A second portion of polyurethane is placed in a second cavity at a time subsequent to placing the first portion of polyurethane in the first cavity. The second portion of polyurethane is allowed to partially care. The first and second cavities are mated together to cure the polyurethane around the core.

Abstract: A substrate coated with a liquid crystal polymer with an intervening tie layer. A second embodiment provides a surface layer disposed on the LCP layer, sandwiching the LCP layer between the surface layer and the substrate. Methods for constructing the above also is provided.

Abstract: A process for manufacturing simple or complex reinforcement preforms for use in resin transfer molding (RTM), structural reaction injection molding (SRIM) or similar molding processes includes applying a thermosetting binder, which is sensitive to selected ultraviolet or microwave radiation, to planar woven or non-woven reinforcing materials, the binder-bearing reinforcing material being placed into a three-dimensional mold and pressed into a desired shape, cured in the mold by applying a corresponding selected ultraviolet or microwave energy thereto to cure and rigidize the binder and hold reinforcement material in the three-dimensional shape resulting in a rigid three-dimensional preform to be used in subsequent molding operations. Structural reinforcements, sub-assemblies and the like may be applied to the preform to enhance the final properties of the final composite structure.

Abstract: A decorative sheet formed by coating a surface of an acrylic resin sheet having a coefficient of kinetic friction with respect to a flat glass plate in the range of 0.2 to 0.9 and a glass transition temperature of 80.degree. C. or below with a pattern layer is inserted in a female mold and a male mold of an injection mold, the decorative sheet is clamped to the female mold, the female and the male mold are joined together to form a cavity in the injection mold, a fluid resin is injected into the cavity so as to fill up the cavity, the resin filling up the cavity is solidified in a sheet-decorated molding having a surface coated with the decorative sheet, the injection mold is opened and the sheet-decorated molding is ejected from the female mold.

Abstract: Rigid substrates containing an adhesive composition on at least one surface are prepared by an injection molding operation. The degree of bonding between the adhesive layer and the substrate is greater than can be achieved using conventional methods for coating substrates with adhesive compositions.

Abstract: Reinforced composite shapes and a method and an apparatus for the production of the reinforced composite shapes. Reinforcement elements such as steel rods, reinforcement fibers and resin are fed into a mold. The reinforcement elements are straightened, aligned and oriented before introduction into the mold.

Abstract: A molding process in which a material with an open cell, porous structure 10 is placed, aligned or supported inside a suitable enclosed holding device. Another molding material 20 is subsequently injected into the said holding device while gas and/or pressure is sequentially applied to the said holding device, causing a synergistic interaction and joining between the said materials to take place. During the processing phase, gas is evenly dispersed throughout the porous core, effectively equalizing cavity pressure and permitting an even flow pattern to exist, encapsulating or sandwiching the said porous structure, thus forming a composite material with physical properties which are substantially greater than the individual components.

Abstract: The invention relates to an electrical isolator having at least one fitting cemented onto an insulating body, in which the insulating body is bonded to the fitting via a cement shell, wherein a laminated layer which contains at least two layers of different materials is applied on the fitting between the cement shell and the fitting, wherein at least one of the layers protects the fitting from corrosion and wherein at least one other layer permits movement between the cement shell and the fitting.

Abstract: A method for making an apertured film for use as a topsheet in absorbent products wherein the film is corona treated on one side, and has received a surfactant application that is distributed to both the corona treated and non-corona treated sides of the film. A method for application of surfactant includes applying the surfactant to one side of the film and rolling the film into a roll while the surfactant is still wet in order to apply surfactant to both sides of the film.

Abstract: A method for fabricating fiber-reinforced composite structures, including centrifuge rotors, by resin transfer molding (RTM) is disclosed. The method involves loading reinforcing fibers into a mold and then injecting resin into the mold to coat the fibers to form the composite structure. Two types of reinforcing fibers are used--fabric preforms at the surfaces of the structure and chopped fibers at the interior of the structure. Also disclosed is a fiber-reinforced composite structure comprising a skin layer of reinforcing fabric, chopped fibers distributed throughout the interior of the structure, and epoxy resin that binds the fabric and chopped fibers together into a fiber-reinforced composite structure. The resin transfer molding method is especially useful for fabricating composite centrifuge rotors.

Abstract: A method for fabricating a composite pressure vessel comprising layering up of an uncured carbon fiber fabric/resin prepreg on a mold. Thereupon an uncured insulating rubber is layered up and combined with the uncured carbon fiber fabric/resin prepreg by autoclaving. This method produces an insulator for a composite pressure vessel which insulator is an aspect of the present invention.

Abstract: Continuous, filament reinforced, wound poles, and the method of making, where the poles are formed by winding a base mandrel with continuous, resin-impregnated filament reinforcement, coaxially abutting an incremental mandrel and winding both the incremental mandrel and the wound first mandrel with a second layer of continuous, resin-impregnated filament reinforcement. The base mandrel is thus wound with two layers of reinforcement. Additional incremental mandrels and additional layers of continuous, resin-impregnated filament reinforcement are successively wound as desired. Preferably all windings occurs prior to the curing of any previous winding. The ends of the mandrels and any cross winding across these ends form stabilizing members within the poles to counteract against compressive forces. The pole has a smooth outer surface when the additional mandrels are properly sized to mate with the wound ends of the previous adjacent mandrel.

Abstract: A very thin inner layer composed of a polymer chosen for its barrier and/or inertness properties is fabricated within a container preform constructed mainly from another polymer, or a structure of polymers. The inner layer on the preform is produced either by a controlled coating method involving coating of the injection mold core rod prior to injection molding or by a coating applied directly to the preform after injection molding. This enables both inner and main layers to be brought together at a time when the interface between them is molten. A tie layer can be employed, when desirable, to enable the layers to be combined without melting the layer interface.

Abstract: A method and apparatus for making a golf ball of selected instruction having an encapsulated core or a non-treated core and a polyurethane cover of selected composition in which equipment is employed for aligning, centering and locating the core in relationship with the molding of the cover thereon.

Abstract: In a process for producing sheet-like polyurethane moldings by impregnation of porous sheets with a polyurethane system and subsequent reaction of the polyurethane system in a mold, the porous sheet is first fully impregnated with a polyurethane component, then fully impregnated with the other polyurethane component and the molding is then produced in a heated mold by reaction of the polyurethane components.

Abstract: A method for forming a composite profile having a foam material introduced therein. The invention provides an inline method for the introduction of a foam material into a composite profile.

Abstract: A window module has a fixed-pane window which is encapsulated by a molded trim piece having an integral portion which extends around an adjacent movable window opening. The integral trim is formed of EPDM. The window module is constructed by placing a window pane, a division post and the end of an extruded EPDM trim strip into a mold into which EPDM is injected to integrate and encapsulate the inserts.

Abstract: Internal thermal protection for a thruster structure, e.g. an end wall and extender structure of a tactical thruster, is made by preparing a low viscosity elastomer base suitable for being mixed with fibers by means of a mechanical mixer without putting the base into solution, by mixing the elastomer base and the fibers so as to obtain a solid composition in finely divided form suitable for being stored, and by molding the composition in situ in order to obtain the thermal protection directly on the structure to be protected. The viscosity of the elastomer base is less than 1500 Pa.s at 50.degree. C., and it vulcanizes at a temperature greater than 120.degree. C.

Abstract: A method of making a toothed belt. A toothed belt is made by guiding a strip of fabric to pass through a thermosetting resin to soak it with thermosetting resin, then the soaked fabric is guided to pass through a pair of toothed rollers to form a series of toothed grooves thereon, thereafter the fabric is guided to pass around a plane roller and simultaneously rubber material is fed into the space between the outer peripheral surface of the plane roller and said fabric. Then, the fabric is wound onto a cylindrical mold having corresponding toothed grooves thereon and its two ends are glued together to loop around the cylindrical mold, then reinforcing cords and rubber sheets are covered over the fabric. Finally, the rubber material is vulcanized to form a toothed belt. Fabrics treated by the method demonstrate considerately greater flexibility or extendibility to comply with bending when under operation. Furthermore, the tooth contour of the belt will be more accurate than conventional ones.

Abstract: Processes are set forth for forming high strength thermoplastic polymer bone fixation devices used, for example, in orthopedic surgery, where "strength" is quantified in terms a given device's pullout strength, tensile modulus, shear strength and breaking torque strength. Products of the aforementioned process are contemplated by the invention as well, with both "bioabsorbable" devices, for example, screws which are absorbable in an animal body and do not need to be removed after the bone in which they are inserted has healed; and non-bioabsorbable devices being described.

Abstract: A sole assembly is made by placing a release film, having a heat activatable adhesive on one side, in a mold and forming a sole in the mold. The adhesive forms an integral part of the completed sole which allows handling of the molded sole without displacing the adhesive or the release film. The molded sole is used by removing the release film, activating the adhesive and bonding the sole to an upper.

Abstract: A single-sided gasketed panel assembly for use as a flush-mounted panel or window in vehicles, buildings, or other structures, as well as a method and apparatus for making such panel assemblies, wherein the panel assembly comprises a sheet-like panel having; a primer layer and at least one polymeric gasket molded to the panel on the primer layer. The primer applied to the panel has a predetermined transition temperature above which improved adhesion properties are exhibited for polymeric gaskets molded thereon when the primer is at or above such temperature.

Abstract: A system and method are disclosed for molding a part, such as a point-of-purchase display, is shown. The system includes a plasticator and press. The molded part comprises an in-molded graphics sheet which becomes molded integral with the part.