Abstract: A method of forming a mold having cavities for molding loop-engageable, hook-shaped fastener elements, includes: supporting a first plate having an outer surface that defines a plane; manipulating a material-cutting beam of a laser along a predetermined curved profile to cut a cavity into the outer surface of the first plate, the predetermined curved profile being generally hook-shaped, the cavity defined by a wall extending into the first plate from the outer surface; in a series of subsequent actions, repeatedly indexing the first plate relative to the laser to direct the material-cutting beam at further positions on the first plate and repeating the step of manipulating the material-cutting beam of the laser relative to the first plate to form a series of cavities, each having a hook-shaped profile; and positioning a second plate adjacent the outer surface of the first plate, the second plate providing a side wall surface for each of the cavities of the first plate, the first plate and the second plate in

Abstract: The present invention pertains to an apertured polymeric film web material provided with a multiplicity of substantially three dimensional surface structures and provided with a multiplicity of fluid transport apertures. In one embodiment, the fluid transport apertures are formed using a process that substantially preserves the integrity of the surface structures. Methods of producing webs are also disclosed. The present invention also includes multi-ply composite structures formed using apertured polymeric film web materials and a sub-ply. The present invention also pertains to absorbent articles which preferably include a topsheet in accordance with the present invention, a backsheet secured to the topsheet, and an absorbent core positioned between the topsheet and the backsheet.

Abstract: An elastic composite sheet of the present invention has an extensible nonwoven fabric, and a thermoplastic elastomer layer bonded to one face of this extensible nonwoven fabric. The extensible nonwoven fabric is one acquired by applying extensibility giving work such as pleating work to a nonwoven fabric including non-elastic fibers, and has elongation of equal to or larger than 100% in at least one direction. The thermoplastic elastomer layer is bonded to the extensible nonwoven fabric in a pattern having a directional property in a direction in which the extensible nonwoven fabric has the elongation of equal to or larger than 100%.

Abstract: A method of manufacturing a headliner assembly for use in the interior compartment of an automotive vehicle comprising the steps of: placing a mold release film onto a concave mold surface of a lower mold assembly for providing a barrier against the mold surface; placing a fiber mat on the mold release film; applying a foamable material directly onto the fiber mat; expanding the foamable material around the fiber mat to embed the fiber mat therein; placing an adhesive film onto a convex mold surface of an upper mold assembly; positioning the lower mold assembly directly beneath the upper mold assembly; moving the upper mold assembly in mating engagement with the lower mold assembly to define a mold cavity between the convex mold surface and concave mold surface; curing the foamable material within the mold cavity; and bonding the mold release film and adhesive film to the foamable material with the fiber mat embedded therebetween.

Abstract: A method for making a friction damper for linen washing machines which have a damper rod that is telescopically driven inside a mantle, and at least a friction element, arranged between said rod and mantle and housed in a housing cavity therefor. The method is based on a first molding step for molding a friction damper casing having a hole for housing said rod and a friction element housing cavity, and a second operating step for making, in said cavity, a plurality of restraining undercut portions for restraining said friction element.

Abstract: Methods and apparatuses for producing fiber-cement soffit building products. In one embodiment of the invention, an apparatus for producing fiber-cement soffits includes a punch assembly, a support assembly facing at least a portion of the punch assembly, and an actuator operatively coupled to at least one of the punch assembly or the support assembly. The punch assembly can include a punch plate and a plurality of punches coupled to the punch plate. Each punch can have a length and a first cross-sectional dimension generally normal to the length. The support assembly can have a support plate, and at least a portion of the support plate is juxtaposed to at least a portion of the punch plate. The support plate can include a plurality of holes arranged in a pattern so that each hole in the portion of the support plate juxtaposed to the punch plate is aligned with a corresponding punch on the punch plate.

Abstract: A method for accelerating the release of a flammable blowing agent from an expanded foam is disclosed. According to the method, an expanded foam structure is perforated to form a first series of channels extending partially through its thickness from a first surface and a second series of channels extending partially through its thickness from a second surface opposite the first surface. The channels provide paths enabling the blowing agent to escape more rapidly from the interior of the expanded foam structure.

Abstract: A sheet of uncured polymer, which is preferably reinforced with multiple layers of fiber, is staged or partially cured to a state in which the sheet is rigid at room temperature. Multiple apertures are drilled into, and preferably through, the sheet. The apertures are for acoustic or laminar flow control, and include holes having diameters in the range of 0.025 to 0.120 inch. In the case in which the fabricated panels must conform to a particular shape, the perforated, partially cured panels are heated to a temperature at which the panel softens, and conformed to the desired surface. The partially cured, perforated sheets are then cured. In order to prevent closure of the drilled holes during the cure, the perforated panel is sandwiched between two layers of glass fabric and cured on an elastomeric tool surface which expands with increases in temperature, forcing the glass fabric to seal the holes during cure. Release coatings are used to aid panel/liner separation.

Abstract: Methods and apparatuses for producing fiber-cement soffit building products. In one embodiment of the invention, an apparatus for producing fiber-cement soffits includes a punch assembly, a support assembly facing at least a portion of the punch assembly, and an actuator operatively coupled to at least one of the punch assembly or the support assembly. The punch assembly can include a punch plate and a plurality of punches coupled to the punch plate. Each punch can have a length and a first cross-sectional dimension generally normal to the length. The support assembly can have a support plate, and at least a portion of the support plate is juxtaposed to at least a portion of the punch plate. The support plate can include a plurality of holes arranged in a pattern so that each hole in the portion of the support plate juxtaposed to the punch plate is aligned with a corresponding punch on the punch plate.

Abstract: A mold for a microlens includes a substrate at least a portion of which is electrically conductive, such as an electrically-conductive substrate or a substrate with an electrode layer, an insulating mask layer formed on the substrate and including an opening or plural openings, and a plated layer electroplated in the opening and on the mask layer. A first condition that a diameter or width (&phgr;) of the opening has a relation of &phgr;≦0.35R, wherein (R) is a radius of curvature of the plated layer right above the opening, or a second condition that the diameter or width (&phgr;) of the opening is &phgr;≦10 &mgr;m, is met.

Abstract: A method for producing filter paper, in particular filter paper for preparing brewed beverages such as coffee or tea employs the steps of producing initially a noncrimped paper of high strength and subsequently rendering this paper capable of filtering through perforation and/or stamping or stamped perforation. The above method is advantageous in that a high production speed of the paper-manufacturing machine results since a crimping device (crimping cylinder, crimping scraper) is no longer required. Accordingly, the bottleneck caused by the crimping device speed is eliminated.

Abstract: Disclosed are a stencil sheet which can smoothly and accurately be perforated even by a small amount of energy while having a required strength and a stencil plate produced from which is easy to control the amount of an ink to be dislocated to an object to be printed and has such an advantage that setoff is small, printability and definition of printed images are excellent, jamming is not caused, and wrinkles are not formed when stencil printing is performed by using the stencil plate; a process for producing the stencil sheet; and a process for producing a stencil plate;

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: In a method for the manufacture of padding material from inherently rigid flat material, such as cardboard packaging or the like, the flat material is cut into parallel strip sections, which in the vicinity of connecting areas spaced in the longitudinal direction of the strips remain partly interconnected. Between the connecting areas the strip sections are so deformed perpendicular to the flat material extension that transversely adjacent strip sections are bent in opposite directions. A manufacturing apparatus is constructed in the manner of a document shredder with a cutting mechanism having cooperating cutting rollers, which have circumferential grooves, which during the passage of the flat material at regular intervals lead to an interruption of the cut.

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: A calender for treatment of a web of a nonwoven textile V made of thermoplastic fibers. The calendar includes a heated embossing roller made of steel and a counter-roller that runs at the same circumference velocity. The local plastification in the nonwoven textile V that is produced at the locations of the raised embossing areas results in a board-like feel of the nonwoven textile V. To reduce this hardness, the web of the nonwoven textile V is broken, after having cooled at least partially.

Abstract: The present invention provides a method for molding an assembly panel comprising the steps of:

Abstract: This invention relates to methods and apparatus for manufacturing shaped polymeric articles by substantially continuous vacuum forming. The method includes providing a sheet of hot polymeric material which is disposed onto a rotating belt having a mold impression. Vacuum pressure is applied to the polymeric material through the belt so as to draw the hot polymeric material into intimate contact with the mold impression to form a patterned sheet portion and a remaining sheet portion. This method thereafter cools at least the patterned sheet portion below a heat deflection temperature of the polymeric material, forms the remaining sheet portion, and then cools the remaining sheet portion below the heat deflection temperature so that features other than the central pattern, such as nail and butt edges, can be mechanically worked into the polymeric sheet.

Abstract: The invention provides a process for producing a phenolic resin-made pulley having a metal insert embedded therein. The process includes a step of sealing a gate of a mold with a gate-sealing pin, and simultaneously therewith or thereafter moving forward the part or the whole of a movable side die of the mold, which was moved backward, to a predetermined position to mold the pulley, whereby the packing density of the molding material in the cavity is increased.

Abstract: Segmentation of a flexible, elongated, strip-shaped substrate having a plurality of encapsulated semiconductor devices mounted thereon, for device singulation, is facilitated by pre-cutting pairs of slots through the substrate at each device mounting area, which slots minimize the amount of substrate material required to be removed during device singulation. Disadvantageous penetration of the slots by liquid encapsulant material is substantially prevented, or at least minimized, by forming slots having burrs or flaps at the upper, mounting surface of the substrate which seal off, or substantially reduce the width of the slots.

Abstract: A pumpkin carving kit includes a cutting die having a closed peripheral configuration defining a shape to be carved into the pumpkin shell, a striking tool for driving the die into the pumpkin shell, and a scoop and scraping tool. The die has a lower cutting edge and an upper driving edge, and a striking surface of the striking tool has a lateral dimension which is greater than the majority of the largest transverse dimension of the striking edge to uniformly distribute impact force to the die. Serrations of the cutting edge of the die are forced into the pumpkin shell to hold the die in position before it is struck. The scoop and scraping tool is used to scrape the thickness of the pumpkin wall so that the die will extend through it.

Abstract: A closure (3) for a container (1), the container having a mouth (16) surrounded by an external flange (7) extending generally away from the mouth, the closure comprising a closure body (9) adapted to extend across the mouth, a skirt (15) which is disposed below the level of the container flange when the closure is initially secured to the container and the mouth is uppermost, the skirt being connected to the margin of the body by a plurality of spaced-apart bridges (19) which lie adjacent to the outer margin of the flange in the initially secured condition of the A closure, and a plurality of upwardly-facing latching formations (20) depending from the skirt (15) and each disposed circumferentially between adjacent bridges (19) as viewed in plan and adapted to latch under the flange (7), the upper portion (23) of the latching formations each lying vertically beneath a respective tool access aperture (25) provided in the margin of the closure body.

Abstract: Mold apparatus and method of production of molded wood strand three-dimensionally carved articles of manufacture using at least one hole punch comprised of a base and a funnel shaped hole-defining portion having a funnel angle of 20 degrees or greater to vertical for producing molded holes at angles of 20 degrees or greater to vertical, to facilitate insertion of items such as a T nut within the molded hole in an assembly-line like fashion.

Abstract: A method for producing a film with through-holes includes using an apparatus having a pair of stretching rollers which sandwich a film therebetween and stretch the film. The producing apparatus further includes a pair of punching rollers which sandwich the film therebetween and punch through-holes in the film. The stretching rollers and the punching rollers are disposed so that the film stretched by the stretching rollers are fed to the punching rollers. The method includes stretching the film by means of the stretching rollers and punching through-holes in the film.

Abstract: This invention relates to methods and apparatus for manufacturing shaped polymeric articles by substantially continuous vacuum forming. The method includes providing a sheet of hot polymeric material which is disposed onto a rotating belt having a mold impression. Vacuum pressure is applied to the polymeric material through the belt so as to draw the hot polymeric material into intimate contact with the mold impression to form a patterned sheet portion and a remaining sheet portion. This method thereafter cools at least the patterned sheet portion below a heat deflection temperature of the polymeric material, forms the remaining sheet portion, and then cools the remaining sheet portion below the heat deflection temperature so that features other than the central pattern, such as nail and butt edges, can be mechanically worked into the polymeric sheet.

Abstract: A process for preweakening the inside of an automotive trim piece cover layer of various constructions by use of a laser beam so as to enable formation of an air bag deployment opening in the trim piece formed at the time the air bag deploys. The laser beam impinges the inside surface of the cover to form a groove scoring or spaced perforations to form a preweakening pattern. A robot arm may be used to move a laser generator so as to form the preweakening pattern. The laser beam can be controlled in accordance with sensed conditions to achieve accurate preweakening, and may also be used to trim substrate panels and to perform other cutting operations.

Abstract: A method of making a fender protective structure having a layer of resilient plastic/elastomer alloy having a delayed elastic response, comprising providing a mold, placing elastomer spacers in the mold, adding the plastic and elastomer to the mold under heat and pressure, and opening the mold and removing the spacers to create voids the alloy.

Abstract: The receptacle consists of a stiff outer receptacle and an easily deformable inner bag resting on said outer receptacle, and is produced in a coextrusion-type blow molding process. The outer receptacle contains at least one pressure compensating opening through which air enters between the outer receptacle and the inner bag whenever receptacle contents is discharged, for instance, by means of a pump. The at least one pressure compensating opening is formed by the measure that a curved wall section of the outer receptacle is cut away by means of a rotating tubular knife or a hollow knife in such a manner that a hole is formed in the outer wall. During the cutting operation, which is carried out at a flat angle, the inner bag is not damaged, but pressed away inwardly.

Abstract: The present invention provides an integral net having a lattice of polymeric material defined by holes traversing the integral net from one surface to the other. The present invention also provides a method for producing an embossed sheet of polymeric material by first contacting a billet of polymeric material with an embossing tool having a plurality of protrusions whereby the embossing tool impresses indentations into the billet to a given depth. Subsequently, the method involves skiving the embossed billet. By this method, an embossed sheet of the polymeric material is removed from the billet, which embossed sheet can be an integral net.

Abstract: A process for preweakening the inside of an automotive trim piece cover layer of various constructions by use of a laser beam so as to enable formation of an air bag deployment opening in the trim piece formed at the time the air bag deploys. The laser beam impinges the inside surface of the cover to form a groove scoring or spaced perforations to form a preweakening pattern. A robot arm may be used to move a laser generator so as to form the preweakening pattern. The laser beam can be controlled in accordance with sensed conditions to achieve accurate preweakening, and may also be used to trim substrate panels and to perform other cutting operations.

Abstract: The invention relates to a method and to an apparatus for perforating a web of material intended to form an outer casing sheet of absorbent articles. As the web is advanced, the web is first provided with a large number of mutually separated cuts in the nip defined between raised plateaus on a matrix cylinder and circumferentially extending knife-edges of a cutting cylinder. The web is then deformed transversely to its plane at parts which border on each cut. The invention also relates to a perforated outer casing sheet which includes recesses in the form of mutually adjacent elongated channel-like grooves.

Abstract: An apertured film for use as a topsheet in absorbent products wherein the film is apertured and includes a plurality of micro-holes and a plurality of large-sized holes. A method of forming the film is disclosed, as well as an absorbent product incorporating the apertured film as a topsheet.

Abstract: A tamper-indicating closure of integrally molded plastic construction that includes a base wall having a peripheral skirt with internal threads for engaging external threads on the finish of a container. A tamper-indicating band is connected to the lower or free edge of the skirt by a plurality of circumferentially spaced integral bridges. At least one of the bridges has a greater circumferential dimension than other of the bridges. A thin integral membrane is disposed in the band immediately circumferentially adjacent to the one bridge, and extends both axially and circumferentially of the band. A stop flange is positioned on the band for engaging a bead on a container to inhibit removal of the closure, such that the membrane and the other bridges rupture upon removal of the closure but the band remains connected to the closure by the one bridge of enlarged circumferential dimension.

Abstract: The present invention relates to a method for producing a thermoplastic material for immobilization and/or protection of a part of the body. The method includes the steps of (1) admixing a thermoplastic material with at least one foaming agent and (2) extruding the admixture at a temperature sufficient to expand the foaming agent and for a specified resident time interval.

Abstract: A method of manufacturing a film-covered article. A moveable press having first and second mold surfaces is moved to an open position. The first mold surface has a sealing surface, and the second mold surface has a cutting surface. A thin flexible film having an offal portion is placed between the first and second mold surfaces. The offal portion is positioned between the sealing and cutting surfaces and acts as a seal between the mold halves. The press is moved to the closed position. The cutting surface contacts the film and partially cuts the offal portion along a perimeter of the film. The offal portion remains positioned between the cutting and sealing surfaces and seals the space between the first and second mold surfaces.

Abstract: A fiberboard mat, whether made by a dry process, a wet process, or dry/wet combination thereof, can be consolidated against a fiber displacement die, contacting and penetrating into a back major surface of the fiberboard mat, to provide fiber-void regions, to achieve a lighter panel, while achieving fiber savings and while maintaining structural integrity and substantially uniform density in the fiber-containing regions. The fiber displacement die includes a plurality of pointed projections that serve to laterally displace fibers, during consolidation of the mat. The displaced fibers are held in their displaced position during the consolidation of the fiberboard mat to provide a consolidated panel having substantially uniform density, or at least a substantially more uniform density, that varies substantially in caliper due to the fiber-void regions.

Abstract: A method of making a perforated laminate wherein a pliable perforation device having plurality of holes and plurality of perforation pins in the holes is assembled on a laminate; the pins are driven through the uncured laminate to perforate the laminate; the laminate is then staged or cured with pins in place; and the pins are then removed from the cured laminate and pushed back into the perforation device for reuse thereof.

Abstract: An extruded plastic strip (1) adapted for use in protecting the edge of an article having a curved surface: said strip including alongitudinal groove (6), a flexible covering portion (2) extending from one side of the longitudinal groove adapted to be placed over and conform with the curve surface of an article to be protected and a plurality of tabs (3-5) hinged to and extending from the other side of the longitudinal groove, wherein said covering portion includes a plurality of holes (9, 10) which are located at or proximate the outer most edge of the covering portion.

Abstract: Miniaturized planar column devices are described for use in liquid phase analysis, the devices comprising microstructures fabricated by laser ablation in a variety of novel support substrates. Devices formed according to the invention include associated laser-ablated features required for function, such as analyte detection means and fluid communication means. Miniaturized columns constructed under the invention find use in any analysis system performed on either small and/or macromolecular solutes in the liquid phase and may employ chromatographic, electrophoretic, electrochromatographic separation means, or any combination thereof.

Abstract: A flexible film interface includes a flexible film; flexible material attached to a portion of the flexible film; surface metallization on the flexible material, the flexible film having at least one via extending therethrough to the surface metallization; and a floating pad structure including floating pad metallization patterned over the flexible material and the surface metallization, a first portion of the floating pad metallization forming a central pad and a second portion of the floating pad metallization forming at least one extension from the central pad and extending into the at least one via.

Abstract: The two ends of an article to be processed which is in the form of a sheet are held by means of a fixed clamp and a movable clamp, the article being held by applying bias by means of a biasing cylinder to the movable clamp in a direction such as would separate it from the fixed clamp and hole-forming processing being performed by means of a laser beam. Since the sheet-like article is held under tension, flatness of even a thin sheet can be maintained and since the underneath space is open, there is no reflection of laser light after passing through the holes that are formed and any processing waste can easily be removed.

Abstract: A method of producing a perforation pattern in a slab of thermoplastic propellant material and the material produced includes subjecting the slab to a perforating press operation in which the press has a patterned array of fixed perforating members arranged according to a first pattern coordinated with a system for advancing and incrementally indexing the slab through the press is used to perforate the slab to create a desired second, denser perforation pattern by subjecting the slab to a series of perforation actions by the patterned array of perforating means coordinated with the indexing of the slab through the press.

Abstract: A Process is described in which the polymer is passed over a former under hydro-static pressure, which may involve passing the material over a die or series of dies for the purpose of imposing multi-axial expansion to the workpiece. Some of the advantages are increased stiffness and reduction in creep. Improved wear is also found.

Abstract: A method for aperturing a laminate. The first step is to provide a laminate having at least one nonwoven web of thermoplastic fibers and at least one elastic member. The laminate is forwarded through a pressure biased nip having a relief patterned nip defining member having a plurality of pattern elements and a nip defining anvil member. The nip defining members are biased towards each other with a predetermined pattern-element loading. Each nip defining member is heated to a temperature that is sufficiently above the melt temperature of the thermoplastic fibers of the nonwoven web and above the melt temperature of the elastic member to enable aperturing of the laminate.

Abstract: A process for substantially covering with at least one non-rigid decorative foil a visible face of a support part of plastic material, so as to obtain a finished part including a decorative inset, including the steps of a) inserting into the mould the foil having a decorative area with the foil having a decorative area, intended to form the inset, and a further area, b) closing the mould at least partially by moving the two mould parts together such that the foil creates a continuous separation of the moulding cavity into a first space and a second space, c) inside the moulding cavity, cutting at least one aperture in the foil at the location of the further area, such that the first and second spaces of the cavity are placed in fluid communication by the at least one aperture which henceforth interrupts the separation between these two spaces so as to enable the plastic material to pass through the at least one aperture, leaving a cut end of the foil in the moulding cavity, d) before and/or after steps b) and

Abstract: A molded product which is molded with thermoplastic resin by a thermal deposition method. The method uses a substantially ring-shaped resistance heating element. A hole is provided for impressing the voltage by inserting the electrode from this hole and impressing the voltage to the resistance heating element. Thereafter the hole is blocked. The electric resistance heating body is disposed between the composition planes of the parts which are to form a body.

Abstract: A process is described for forming a lighting louver that includes a plurality of louver members. The process includes the steps of providing a sheet of thermoformable material and heating the sheet to a pliable state. A further step includes providing a forming mandrel having a series of mandrel partitions arranged with spaces between the partitions. The heated sheet is positioned over the forming mandrel, and is forced against the forming mandrel to form the heated sheet over the mandrel partitions and thereby produce a formed louver blank including formed louver segments that conform to the mandrel partitions and webbing segments that span the spaces between the partitions on the forming mandrel. In one preferred form the webbing segments are removed. In another preferred form, transparent webbing segments are formed that do not require removal and will transmit light. The webbing segments in the first form are removed from the louver blank to form light transmissive openings through the louver blank.

Abstract: A method for the manufacture of a screen useful for forming three-dimensional films, the screens and the three-dimensional films produced using those screens are disclosed. In forming a screen, a substrate material is applied to a base. A predetermined amount of portions of the substrate are removed to form a predetermined pattern in the substrate. A screen material is applied to the patterned substrate material. A predetermined amount of portions of the screen material are removed to form a predetermined pattern in the screen material. The predetermined pattern in the screen defines a plurality of first perforations in the screen material. The substrate material is removed from the screen material, such that second perforations are formed in the screen, whereby each first perforation is in communication with an adjacent second perforation.

Abstract: A one-way see-through panel assembly enhanced by a retroreflective surface. The panel assembly has a first panel which has a dark light-absorbing surface and an opposite light reflecting surface. A retroreflective sheet is applied over the light reflecting surface to form an assembly. Light passageways, either perforations or a pattern of discrete transparent areas, are provided in the assembly. An image is imprinted on either the surface of the retroreflective panel or the light reflecting surface. The method includes mechanically perforating the assembly which is facilitated by the retroreflective sheet having non-glass reflective formations thereon.

Abstract: This invention relates to a method of molding a double-wall bottle consisting of an outer bottle (12) and an inner bottle (14). A outer bottle (12) is first formed from a first preform by biaxial Stretch blow molding. After this molding step, a plurality of air vent holes (24) are formed in a biaxially orientated region of the outer bottle (12). Next, a second preform (70) and the outer bottle (12) are set together within a first blow cavity mold (100). Subsequently, the inner bottle (24) is formed by biaxial stretch blow molding from the second preform (70) while the air within the outer bottler (12) is expelled through the air vent holes (24). Circumferential concave ribs (22) are formed around the entire circumference of the outer bottle (12), and at least one of the air vent holes (24) is formed in a region either inside or outside the region in which the circumferential concave ribs are formed.