Abstract: The present invention is direct to angular border on three dimensional sheet material and method of producing. This invention is producing an attractive and finely finished article.

Abstract: A method for producing a zipper for use in the production of reclosable plastic bags of the type having the zipper extending across a top end of the bag. The zipper has a first profile member and a second profile member that is interengageable with the first profile member. At bag length intervals of the zipper notches are formed by removing at least a portion of the first profile member and a portion of said second profile member. A mold is positioned about each of the notches and a molten thermoplastic material is introduced into the mold cavity filling the notch and extending beyond the notch and over the zipper top so that when the molten thermoplastic material is cooled an end stop is formed in situ at each of said notches.

Abstract: A method for medical balloon fabrication comprising the steps of securing a balloon with a mold by inflating it and then enlarging the inner diameter of the balloon. The devices of the invention comprise a fixture with a mold configured to hold the inflated balloon and a drill that can be centered with the mold to enlarge the inner diameter of the balloon.

Abstract: A manufacturing method for a filter element having a filter portion and a flange portion formed along an outer periphery of the filter portion to protrude outwardly. First, a corrugated intermediate product having plural ridges of the filter element is formed by folding. Next, the flange portion is formed integrally with the filter portion by pressing an outer peripheral portion of the intermediate product at a high temperature. While the flange portion is formed, each of sides of the intermediate product extending in parallel with the ridges is restricted to a position corresponding to a shape of the filter element by plural forming jigs. Therefore, sides of the flange portion extending in parallel with the ridges are formed simultaneously when the flange portion is formed and do not need to be trimmed after forming. As a result, a material of the filter element is less wasted.

Abstract: A method of making an interior trim panel for attachment to structure of a vehicle includes the steps of loading a trim blank into a cavity of a mold and loading an edge of the trim blank on a movable slide of the mold. The method also includes the steps of depositing a molten thermoplastic material onto a core of the mold and partially closing the mold. The method further includes the steps of moving the slide into a channel of the core, completely closing the mold, and forcing the molten plastic material into a down-turned flange area of the mold to form the interior trim panel with a down-turned flange.

Abstract: This invention relates to a splittable medical device incorporating two sets of preferential tear lines. The first set of preferential tear lines preferably includes two longitudinally extending skives formed along the exterior surface of the proximal portion of the splittable medical device. The second set of preferential tear lines preferably includes a plurality of grooves formed along a distal portion of the interior portion of the splittable medical device. The skives should be substantially aligned with some of the grooves. This configuration facilitates splitting of the medical device along the skives and along one or more of the grooves to allow a clinician to split the medical device completely into two pieces. This invention includes a special mandrel having a plurality of ribs formed along a distal portion thereof and process that is used to manufacture the splittable medical device.

Abstract: A method of forming a joint (32) between two plastics extrusions (10) is disclosed which comprises mitring the extrusions (10) so that they form the desired angle to one another removing part of the rear face of each extrusion (10) placing the mitred extrusions in a mould and injecting a resin material whereby to bond the extrusions (10) to one another and produce the desired joint (32) configuration. Because the front surface (24) of the joint in accordance with the invention is entirely made up from the original extrusion, there are no problems with raised sight-lines, colour differentials, surface differences, or colour matching. Moreover, the method of the invention allows a corner to be produced which has a clean right angled rather than radiused inner portion.

Abstract: A molding method and a metal-covered plastic component such as partial or entire fascia, body side moldings, and the like, which have bright surface requirements and which includes a film sheet and a one-piece thermoplastic elastomeric structural carrier are provided. The film sheet includes a decorative layer of metal such as chrome. A plastic layer of the film sheet on which the layer of metal is formed is selected from a group consisting of polyester, polyurethane and polycarbonate. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the step of forming a preform which is securely positioned within the injection mold during injection molding to form the plastic part.

Abstract: A process for manufacturing ligneous material board with improved surface slip-resistance. The process includes a mechanical ablation step which roughens the surfaces of the board to obtain slip-resistant textured surfaces.

Abstract: In a method of producing a resin gear, after applying a gear cutting having a gear cutting direction toward the gate forming portion onto an outer periphery surface of a resin rim layer, the gate forming portion is cut and removed.

Abstract: A method for forming a spigot on a double-walled pipe and spigots formed by this method are described. The outer wall and an intermediate space of a double-walled pipe is removed from one end of the pipe over the desired chamfer length, and a preformed annular resilient bevel is placed around the remaining inner wall. This method is convenient, requires limited materials and tools, provides easy access to a porous intermediate space for sealing, and does not introduce residual stress to the spigot. Furthermore, the properties of the spigot depend primarily upon the properties of the annular resilient bevel, increasing the probability of achieving a high quality and robust seal.

Abstract: A method and system for forming a medical device component having a section with a reduced wall thickness, and the device component formed thereby. The method generally comprises rotating a medical device component while a material removal device is placed into contact with a section of the rotating component, to thereby remove material therefrom. In one embodiment, the medical device component is a catheter balloon in which at least one of the proximal and distal shaft sections of the balloon is thinned according to the method of the invention. In another embodiment, the component is a polymeric tube, including polymeric tubes useful in forming a distal tip or catheter shaft section of a catheter.

Abstract: A process is described for making gourd molds useful in the production of decorative ceramic and other articles which bear the textures of the gourd interior. Articles produced may also serve as models for use in the manufacture of production molds. Steps in making the gourd molds include selection, cutting, and removal of pulp; steps in using the gourd molds include treating with a release agent, casting, and removal of the gourd mold from the molded article.

Abstract: A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: An insulation piece for joining with a similar piece to surround a pipe elbow of a larger diameter such as greater than 9 inches outside diameter is formed by cutting from a block of the insulation material.

Abstract: An optical recording head is provided which includes a slider body having a leading edge. A void is formed in the slider body to receive a sphere of optically transparent material. The sphere is inserted into the void such that a portion of the sphere protrudes from the slider body. The protruding portion is lapped to be coplanar with a surface of the slider body to form a near-field lens. A mesa may be formed onto the lapped portion and may include a coil. The slider body, mesa, near-field lens, and coil may be formed in one batch process.

Abstract: A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: The present invention is a machine and process for manufacturing an article such as a body board having a pre-shaped core member having a top surface and a bottom surface, a top skin having a top and bottom surfaces, a perimeter portion, and a perimeter edge, and a bottom skin having a perimeter portion. In one embodiment, the machine of the present invention comprises a first mold halve having a lower surface and a second mold halve having a lower surface and a plurality of side walls extending upward from the bottom surface. The second mold further comprising at least one seam member engaged with each side surface. The machine further comprises a control unit for opening and closing the first and second mold halves.

Abstract: A method of producing a lordosis support (12) with a supporting element (22) of plastic of adjustable curvature at rods (18) of a lattice mat (10), formed by longitudinal and transverse rods (14, 16, 18), wherein the rods (14, 16, 18) are introduced into an injection mold (42, 44) for the supporting element (22) and, during the injection molding of the supporting element (22), are embedded in the latter.

Abstract: A surface covering, particularly a sheet vinyl floor or wall covering, wherein a decorative wet laid felt sheet is employed to impart decorative effects to the finished product. The decorative felt sheet is overlaid at least with a translucent wearlayer and optional decoration can be provided by printing, decorative particles, mechanical and/or chemical embossing and combinations thereof.

Abstract: A method for manufacturing a honeycomb structure that is to be affixed to a desired location on an automobile interior component is disclosed. A mold half is formed with an shape defining cavity that is contoured to have generally the same as the shape of one side of the honeycomb structure that is to be formed. A plurality of vertically indexed straws that, include a central core formed from a first thermoplastic material having a relatively high melting point and an outer layer of second thermoplastic material that has a relatively low melting point, are placed in contact with the shape defining cavity of the mold. In order to form the honeycomb structure, the mold is heated to a temperature that melts the second thermoplastic material but does not melt the first thermoplastic material, thereby allowing the indexed straws to be bonded together and form one side of the honeycomb structure.

Abstract: Polymeric films including a layer of propylene resin having microvoids therein, the microvoids having been formed by stretching a web containing the beta-form of polypropylene, have shown low static cling when being unwound from rolls in labelling operations and also during destacking of pre-formed labels. The invention provides labels formed from such films.

Abstract: A method for packing a stationary phase into a small diameter fluid passageway or flow channel. Capillary action is employed to distribute a stationary phase uniformly along both the length and diameter of the flow channel. The method disclosed here: 1) eliminates the need for high pressure pumps and fittings and the safety hazards associated therewith; 2) allows the use of readily available commercial microparticles, either coated or uncoated, as the stationary phase; 3) provides for different types of particles, different particle sizes, and different particle size distributions to be packed in sequence, or simultaneously; 4) eliminates the need for plugging the flow channel prior to adding the stationary phase to retain the packing particles; and 5) many capillaries can be filled simultaneously.

Abstract: A method of manufacturing an interconnector that is interposed between a pair of terminal plates each having electrodes arranged in a predetermined pattern, for electrically connecting the electrodes of the terminal plates, including arranging positioning plates in a container and inserting conductive wires into through holes of the positioning plates. Then forming a stacked body by alternately forming stacked insulating sheet layers and synthetic resin layers, in the container and thereafter cutting the stacked body at a middle portion of each synthetic resin layer before separating the synthetic resin layers from the insulating sheet layers, thereby forming interconnectors.

Abstract: A method of twin-sheet vacuum forming plastic articles having the steps of clamping two parallel sheets of thermoplastic synthetic resin in a vertical orientation to a clamping tray and blowing air between the parallel sheets thereby creating a hollow cavity between the two parallel sheets. The two parallel sheets are then heated to molding temperature between two vertically oriented heaters. The two parallel sheets are disposed between opposing mold cavities of a vertically oriented split mold wherein the mold cavities have a contour conforming the configuration of the desired article. A negative pressure is applied to suction holes provided in the mold cavities which draw the two parallel sheets against each opposing mold cavity. The split mold is then clamped together to form a pinch off around the perimeter of the hollow cavity thereby forming a molded hollow part still disposed within the clamping tray.

Abstract: A flexible graphite sheet exhibiting enhanced isotropy is provided. In addition, an apparatus, system and method for continuously producing a resin-impregnated flexible graphite sheet is also provided.

Abstract: A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: A method for forming convexities and/or concavities on cloths for a garment at almost entire portions of the garment or any desired portion of the garment without any substantial limitation from a design point of view. The method for forming a garment having convexities and/or concavities which can expand and contract in both the weft and wrap directions like a knitted fabric. Cloths including thermoplastic fiber are cut into parts of the garment, the parts are sewn in a shape of the garment. The garment is overlaid on a thermo-shrinkable cloth. They are sewn together with stitches of water-soluble threads. The sewn cloths are heated under dry heat and without applying any pressure to the cloths so as to permit the thermo-shrinkable cloth to shrink and form convexities and/or concavities on the cloths of the garment. The water-soluble threads are solved and removed, and the cloths of the garment are separated from the thermo-shrinkable cloth.

Abstract: A method of manufacturing a part having at least one mechanically weakened area includes a step of producing a thermoplastics material part and at least one cycle of steps entailing forming a localized opening through an area of the part, heating the part locally by means of a heating probe so as to render the aforementioned area of the part plastic, and using a punch to modify the geometry of the area rendered plastic so as to delimit in the part a mechanically weakened area constituting a hole or hole precursor.

Abstract: Parallel spaced shallow grooves are cut within the surface of an existing reinforced concrete member in the direction of bending and at locations where existing tensile reinforcing is inadequate. A curable polymer adhesive resin, such as an epoxy resin, is inserted into each groove and an elongated fiber reinforcing element, such as a composite rod with continuous carbon fibers, is positioned within each groove, substantially filling the groove, so that the minimum volume adhesive resin surrounds the reinforcing element. The adhesive resin within each groove is formed flush with the surface and allowed to cure to bond each reinforcing element to the concrete defining the groove. The grooves and reinforcing elements extend within the top surface of a concrete slab across a beam or support for the slab, extend within the bottom surface of the slab at least fifty percent of the distance between adjacent supports for the slab, or within a vertical surface of a concrete or masonry wall or column.

Abstract: A method for manufacturing an E.V.A. foamed sports equipment includes preparing and stirring an E.V.A. foamable mixture, then integrally forming the foamable mixture into a sports equipment blank with a constantly reduced scale, the constantly reduced scaled sports equipment blank being placed in a reduced scaled heat forming mold to be heated at the temperature of 180° C., then opening the reduced scaled heat forming mold after a pre-determined period of time, the constantly reduced scaled sports equipment blank in contact with the air being expanded into a foamed sports equipment blank, then, placing the foamed sports equipment blank and ornamental strips into a constantly scaled pattern generating mold to be heat pressed and melted into a unity, the generating mold being evacuated so that the periphery of the foamed sports equipment blank is attached to the pattern generating mold so as to form a foamed sports equipment product with a precise knurl pattern being formed thereon.

Abstract: A method for making a part with at least a mechanically weakened zone, including a step of producing a thermoplastic part (10), and at least a cycle of steps which include: locally producing a through recess in a zone of the part having a constant thickness; locally heating the part using a heat probe (15) so as to make the zone of the part plastic; modifying with a punch (15) the geometry of the resulting plastic zone so as to define in the part a mechanically weakened zone constituting a hole or a hole outline.

Abstract: Methods for manufacturing panel units may include applying a cover tape to a surface of a panel in such a way as to substantially extend along a periphery of the panel. An extrusion molding die may be moved relative to the panel in such a way that the extrusion molding die moves along the periphery of the panel while at least partially contacting the cover tape applied to the panel. At the same time, a molten molding material may be extruded from the extrusion molding die, thereby integrally forming a molded article on the periphery of the panel. The cover tape may be then removed from the surface of the panel in order to produce a panel unit having the molded article disposed along the periphery of the panel.

Abstract: The present invention is directed to a helical ribbon, and method and apparatus for making same. The helical ribbon is formed from a resilient ribbon having first and second surfaces and a length substantially longer than its width. A plurality of spaced-apart crimps extending across the width of the ribbon are formed in the first surface of said ribbon whereby said plurality of crimps cause the ribbon to curl back onto itself. The resilient ribbon used to form the helical coil of the invention must be sufficiently rigid to take and hold a crimp rather than merely bending, yet be pliable enough that the process of forming the crimp does not cause the ribbon to break. The invention also includes decorative items made from one or more of such helical ribbon(s).

Abstract: A method of forming fiber reinforced polymer matrix composite structures having a low volume fraction of fiber reinforcement and carefully controlled thicknesses is provided. The method enables the production of composite structures having a fiber volume fraction of less than about 0.5 through the use of vacuum bag molding, thereby eliminating the need for expensive closed molds, The method also eliminates the occurrence of “racetracking” of uncured resin during the resin infusion process.

Abstract: The invention is directed to a method of forming a distal tip on a catheter. The method includes defining an area on the distal end of a polymeric tube, creating at least one void by removing at least some of the material within the area, and sealing the cut edge closed. The area is defined by a boundary, which includes a first location on the distal tip, a second location on the distal tip radially spaced apart from the first location, and a third location proximal to the distal tip. The preferred area is a cut having a V-shape. This method creates a superior catheter tip profile, specifically for soft tips.

Abstract: A gel-based or solid item with one or more decorative voids. Gel-based and solid compositions typically used for air fresheners or candles permit the inclusion of shaped objects that, when removed once the composition cures sufficiently, create decorative voids. Depending upon the shape of the objects used, these voids may possess a high degree of detail. Highly detailed decorative objects often produce an ice sculpture-like appearance to the decorative void. Additional effects, such as glitter or a pearl-like appearance, may be added to enhance the appearance of the decorative void.

Abstract: A method of making an interior trim panel for attachment to structure of a vehicle includes the steps of loading a trim blank into a cavity of a mold and loading an edge of the trim blank on a movable slide of the mold. The method also includes the steps of depositing a molten thermoplastic material onto a core of the mold and partially closing the mold. The method further includes the steps of moving the slide into a channel of the core, completely closing the mold, and forcing the molten plastic material into a down-turned flange area of the mold to form the interior trim panel with a down-turned flange.

Abstract: A film production process having a film tentering step and a recovering step, characterized by detecting the side edge positions of the film running toward the recovering step, transferring the film running direction based on the detected information, and controlling the clamp start position of the film arriving at a tenter in the tentering step by clamp means, in the transverse direction of the film. A film production process having a film tentering step, characterized by controlling the clamp start position of a film arriving at a tenter by clamp means, in the range from 5 mm to 1,000 mm from the tip of the film in the longitudinal direction of the film.

Abstract: Stripped porous polymer film and a method for making such film from substantially heterogeneous porous polymer film are described. The heterogeneous film has surface characteristics that are different from the characteristics of the interior bulk material, and the method comprises mechanically stripping at least a portion of at least one surface layer from the heterogeneous film. The stripped porous polymer film may be incorporated into composite membranes. Such composite membranes are particularly suitable for incorporation into membrane electrode assemblies for use in electrochemical cells, including electrochemical fuel cells.

Abstract: A method of integrally forming a bicycle front fork formed from a compound material including the steps of preparing a mold of a length greater than the front fork; forming a curved groove at a rear end of the mold; winding a blank of a front fork shape from a compound material and placing the blank into the mold; inserting an inflatable tube into the blank from a vertical tube at an upper end thereof through a forced portion on one side and round the curved groove and then through a formed portion on the other side to have the end in the vertical tube; and forming a front fork from the blank by inflation, heating and applying pressure.

Abstract: A method of making molded parts employing Shape Deposition Manufacturing (SDM) techniques. First, SDM processes are used to make a layered structure having support segments and mold segments. The support segments are made of material which may be removed from the mold segments (e.g. dissolved or melted). The mold segments are made of a material which can function as a mold. The mold and support segments are sequentially deposited (e.g. in layers) and shaped (e.g. machined) to form a mold. The support segments define the shape of the part to be manufactured. The mold segments are removed from the support segments by dissolving or melting away the support segments, leaving an empty mold. Then, part material is cast into the empty mold. The mold is removed, providing a molded part. The part material can be a gelcasting slurry, for example. The present method provides homogeneous or heterogeneous parts having shapes which are accurately defined by the SDM process.

Abstract: An intravascular medical catheter and method of manufacturing a medical catheter are provided herein. The medical catheter includes a catheter shaft having an inner liner, a reinforcing section and an outer shell. As provided herein, a groove is formed in the outer shell of the catheter shaft near a distal end of the catheter shaft with a laser. The groove can be filled with a fill section which is made of a relatively soft material. This improves the flexibility of the distal end so that the medical catheter has improved tracking and movement in the body vessel. Further, because the reinforcing section is continuous under the groove, the catheter shaft is durable and inhibits kinking during movement in the body vessel.

Abstract: The invention relates to a process for obtaining single-piece capsules made of a plastic material, which comprises: a press-forming phase for obtaining a single-piece capsule (1) provided with a skirt (2) connected to a lower zone (1a) of the capsule; a folding phase of the skirt (2) internalwise of the capsule, obtained by plastic deformation of the connection zone (3) between the skirt (2) and be capsule; a cutting phase of the lower zone of the capsule, obtained by a radially-directed insertion of blades (4a, 4b) which are shaped such as to obtain cuts (5a, 5b) of predetermined shape and size.

Abstract: For implant molding of toothbrushes pre-cut and pre-rounded fiber of thermoplastic material are used. Loose fibers are presented to an endrounding tool in a tuft or bundle and the free ends of the fibers are exposed to a working surface of the tool. Relative movement between the fiber ends and working surface causes the material of the fibers to be heated by friction of a predetermined intensity. The fibers while they are exposed to the working surface of the tool are permitted to flex laterally and are held in an axial direction of the tuft or bundle with their free ends commonly defining a surface different from a plane which is perpendicular to the axial direction, thereby achieving a substantially consistent flexing resistance throughout the cross-section of the tuft or bundle with respect to lateral deflection upon engagement by the endrounding tool.

Abstract: A method is provided for manufacturing a painted plastic component having a badge, emblem or other ornamentation, such as air bag covers having a badge, or wherein the component is the badge itself. The method includes providing a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: A forming method for a cup bottom containing an object. The method includes a first step of forming a cup body with a thick bottom provided with a large recess opening to a lower side, a second step of filling transparent resin in the large recess, a third step of burying an object such as a small insect, a plant, a flower, a grass, water, etc., and a fourth step of scraping a lower edge of the large recess flat and smooth so as to enable the cup to stand on something. This a cup is made with a three-dimensional object embedded therein.

Abstract: A memorial product generated from the cremation remains of a deceased human or animal whereby a predetermined amount of bone ash is combined with a predetermined amount of a glass forming additive. In addition, a glass modifier may be added to enchance the durability of the final solid product. A flux may also be added to reduce the melting temperature of the mixture. These additives are combined with bone ash and milled to a desired particulate size to form a powder mixture. The mixture is heated to a melting temperature for a resident time to form a glass melt which is then poured into a mold. The cast or molded form is annealed for a resident time at a predetermined temperature to avoid stress fracture or crystalization from cooling too quickly or slowly.

Abstract: A method for cutting a honeycomb core comprising a plurality of hollow tubular cells, wherein the method comprises the steps of: filling or coating a hollow tubular cell of the honeycomb core with a resin composition that is in a gel state at an ordinary temperature; cooling the resin composition to a solid state; cutting the hollow tubular cell together with the resin composition in the solid state; allowing to stand or heating the resin composition to a gel state; and removing the resin composition in the gel state from the hollow tubular cell.

Abstract: An embedding hole is formed in a base made of thermoplastic resin, an embedded part is inserted in the embedding hole, the base is subjected to heating treatment for softening the base to bring the base into an elastomeric region and restraining treatment for restricting outward thermal expansion of the base to thereby expand the base in an inward direction of the embedding hole 2a to reduce a hole diameter and to deform a hole wall of the embedding hole along a shape of an outer wall face of the embedded part and to bring the hole wall into close contact with the outer wall face, and then the base is cooled and hardened.