Abstract: Footbeds for footwear, especially sandals, are formed from weldable plastic materials, such as industrial and commercial carpeting, and are provided with patterns welded into the material and with decorative prints or patterns welded to the physical patterns. The footbeds are very decorative in appearance and produce very saleable footwear products. A process for conveniently and economically producing the decorative footbeds is also disclosed.

Abstract: In order to produce a one- or multidimensional detector array (9; 15, 17; 70) for detecting electromagnetic radiation, in particular for detecting X-rays, a layer composite (1) is produced. The latter has a sensor layer (3) with a material (M) sensitive to the radiation, and a carrier layer (5). In order to subdivide the sensor layer (3) into individual elements (E11, E12, . . . E1m, E21, . . . Enm) that are isolated from one another, separating spaces (7) are introduced into the sensor layer (3) by material (M) being removed. Preferably, a reflector material (R) is introduced or filled into the separating spaces (7). In order to produce a plurality of one-dimensional detector arrays (70), a structure of elements (E11, E12, . . . E1m, E21, . . . Enm) arranged in a matrix-like manner, which structure is produced by the separating spaces (7) is broken down into row portions (52, 53, . . . 63) or into column portions.

Abstract: Processes are provided for formation of complex shapes by embossing of a sheet of flexible graphite material. In one approach, a sheet (26) of material is provided with a variable resin concentration across a selected dimension of the sheet, and the position of the variable which will result in thinner areas in the embossed articles. In a second approach, recesses are provided in the embossing rollers (30 and/or 32) to accomodate material flow during embossing. These recesses result in protrusions formed on the articles, which protrusions must then be removed in a machining operation.

Abstract: A method for manufacturing fiber-reinforced moldings in a resin mat apparatus. The manufacturing procedure is performed in a continuous manner of operation from the mixing of the components of the resin mixture to the procedure of pressing a molding. The apparatus includes a controlled-temperature, continuous thickening unit for a time-prescribed maturation process of the endless resin mat. Endless felts carry the endless resin mat in a meander or serpentine path through the continuous thickening unit.

Abstract: The present invention relates to a process for making polymer tapes utilizing metallocene catalysts. An isotactic propylene polymer is prepared by polymerizing propylene in the presence of an isospecific metallocene catalyst. The resulting polypropylene is heated, extruded and withdrawn as a sheet. The sheet is then slit longitudinally into tape segments and drawn in the longitudinal direction to a draw ratio of at least about 4.5:1 to produce an oriented tape. It has been found that these polypropylene tapes have different characteristics than those polypropylene tapes produced using Ziegler-Natta catalyst drawn at the same draw ratios.

Abstract: The present invention provides cellulosic fibers having high wet bulk and methods for their preparation. In one embodiment, the invention provides cellulosic fibers catalytically crosslinked with glyoxal and, optionally, a glycol. In another embodiment, cellulosic fibers are crosslinked with a combination of glyoxal and a glyoxal-derived resin selected from the group consisting of a glyoxal/polyol condensate, a cyclic urea/glyoxal/polyol condensate, a cyclic urea/glyoxal condensate, and mixtures thereof.

Abstract: A method and apparatus for vacuum thermoforming disposable drink cups lids including the step of imparting printing to the lids in two or more colors while they are in contact with the vacuum thermoforming platen.

Abstract: Method for producing decorative grass, such as Easter grass, from a sheet or web of material having printed material and/or embossed patterns thereon. The printed material and embossed patterns may be in register or out of register with one another. A method for producing decorative grass having the appearance of a blend of decorative grasses is also disclosed.

Abstract: A non-woven fiber pad having a convoluted surface formed by cutting a non-woven fiber batt having a plurality of low melt synthetic fibers. The non-woven batt is compressed generally toward a cutting device by a pair of counter-rotating drums having convoluted surfaces.

Abstract: A process for producing patterned elastic sheetings comprises the steps of providing a pair of press rollers having opposite press surfaces respectively formed with at least one protrusion and one indentation, providing a laminate having at least two elastic sheet layers and one interface, placing the laminate between the rollers and causing the protrusion to press the laminate into the indentation so as to deform the laminate until the interface is deformed, cutting the laminate along a cutting plane that passes between the rollers and that passes through the laminate to divide the laminate into two parts, and causing the laminate to exit from the rollers to return the laminate to a non-deformed state. The interface deforms in a direction transverse to the cutting plane, and a pattern is formed in the laminate on two sides of the cutting plane after the laminate exits.

Abstract: A trim press article handling apparatus includes a punch plate, a die plate, a plunger, and a receiver. The punch plate has a punch, and the die plate has a die cooperating in relative movement with the punch plate to sever articles from a thermoformable web. The plunger is carried by one of the punch plate and the die plate having a tapered advancing head. The receiver is carried by the other of the punch plate and the die plate having a tapered recess configured to receive the plunger. A tapered article locator provided within a thermoformed web also having articles therein is captured between the plunger and the receiver as the punch plate and die plate are brought together there about, thereby imparting alignment of an article in the web between the punch and the die. A method for aligning and severing articles from a web is also provided.

Abstract: A method of forming a thin film strip. The method comprises coating a liner substrate with a wet slurry of film forming ingredients and drying the wet slurry in a drying oven to form a film. A moisture content of the film is measured as the film exits the drying oven and the film is rewound on itself. The rewound film is then stored in a minimal moisture loss environment during a curing process.

Abstract: A method to produce an electrically conductive floor covering made of first particles of a polymer material which are surrounded with electrically conductive second particles and compressed in the intermediate space between the top and bottom sides of the floor covering, with the floor covering having at least one cut surface and the electrically conductive second particles forming conductive paths which connect the upper side and the lower side of the floor covering in an electrically conductive way, in which the first particles comprise at least one granulated elastomer material and form a matrix, in which the second particles form electric conductive paths along the particle boundaries of the first particles.

Abstract: An enclosed pest control device includes a covered tray carrying a tacky glue, bait, etc. The cover is vacuum formed of a transparent thermoplastic sheet and includes an open ended igloo vestibule which leads to the interior. During manufacture, the vestibule open end is formed by cutting the vestibule in a plane transverse to the plane of the tray, without a backing support. An array of covers is formed of a single sheet with continuous vestibules joining the ends of adjacent covers in a row such that a single cut through each vestibule will form two open ended vestibules without wasted material.

Abstract: A method and apparatus for manufacturing a wire or cord for welding floor coverings, such as linoleum or artificial fiber floor covering. The wire or cord forms a fixed joint via thermal processes between separation edges of adjacent sections of floor coverings provided with colors and patterns such that minimal difference is apparent between the floor covering and the cord or wire. A mixture of colored granules is subjected to a process of mixing, heating, and cooling adapted to form solid sheets that are cut to form the cord or wire.

Abstract: A method for manufacturing composite parts includes positioning a plurality of composite layers on an application surface formed by a plurality of tooling members and filler members on a mandrel. A part formation aid is disposed on the composite layers above each tooling member. The filler members are then removed, and the composite layers slit over the recesses. The mandrel, the tooling members, the composite layers, and the part formation aids are placed in a vacuum bag. As the bag is evacuated, each part formation aid forces the side edge of the composite layers formed by the slit around the respective tooling member, thereby forming a composite part with a desired shape, thickness, and density. In an alternate embodiment, a flanged composite panel is formed around a rectangular mandrel after positioning composite layers on an outer surface of the mandrel and an outer surface of a filler member disposed on one end of the mandrel.

Abstract: Processes are provided for formation of complex shapes by embossing of a sheet of flexible graphite material. In one approach, a sheet of material is provided with a variable resin concentration across its width, and the position of the variable resin concentration is correlated with the position of embossing features which will result in thinner areas in the embossed articles. In a second approach, recesses are provided in the embossing rollers to accommodate material flow during embossing. These recesses result in protrusions formed on the articles, which protrusions must then be removed in a machining operation.

Abstract: The specification discloses a method for extrusion coating multiple substrate webs on a dual or tandem extruder system having multiple extruder stations. The method includes as an initial step providing a first substrate web and a second substrate web wherein each of the first and second substrate webs has a coating side and an underside. The webs are temporarily joined to form a composite web wherein the respective coating sides face outward and the respective undersides face one another. A first polymer coating is extruded on the coating side of the first web at a first extrusion station. Subsequently, a second polymer coating is extruded on the coating side of the second web at a second extrusion station. The extrusion coated first and second webs are then separated. The invention enables more efficient and economical use of dual or tandem extruder systems.

Abstract: Polymeric multilayer optical films, and laminate bodies that include such films, are cut or subdivided into one or more discrete pieces by removably applying a first and second liner to opposed major surfaces of the multilayer optical film. Laser radiation is then directed at the multilayer optical film through the first liner in such a way as to produce cut lines that define a plurality of pieces of the first liner and of the multilayer optical film. Thereafter, the plurality of pieces of the first liner are removed from the plurality of pieces of the multilayer optical film while the pieces of multilayer optical film are supported by the second liner. Application of the first liner to the multilayer optical film can be accomplished with electrostatics.

Abstract: A sheet of plastics material is continuously extruded onto the upper run of an endless conveyor which carries aluminum vacuum mold plates each defining a cavity with a shingle pattern. The sheet is progressively vacuum-formed into the mold plate cavities, and opposite longitudinal upper and lower portions of the sheet are progressively vacuum-formed, with traveling plug assist in one embodiment, to define shingle panels with hook-shaped lower portions and upper portions defining grooves for receiving the lower portions. The upper portion of the sheet is punched with longitudinally spaced slots to form a nailing flange, and the sheet is then cut laterally at longitudinally spaced intervals to produce elongated siding panels each having integrally connected shingle panels. The shingle panels may have different bottom configurations or profiles and are interchangeable.

Abstract: A method for making freeform-fabricated core composite articles using freeform-fabricated machine. The articles are capable of being utilized as end products rather than prototype models by creating a core having an interior structure to provide strength to the core and to enhance the strength to weight ratio of the article.

Abstract: Method for producing decorative grass, such as Easter grass, from a sheet or web of material having a decorative pattern thereon. The decorative pattern may be printed material and/or embossed patterns thereon, or a non-linear side edge that provides the decorative grass with a contoured configuration.

Abstract: A continuous process for manufacturing decorative panels includes the steps of forming a first continuous fiber reinforced resin layer, laying a continuous decorated sheet on the first fiber reinforced resin layer, forming a second continuous fiber reinforced resin layer on the continuous decorated sheet, eliminating a substratum of the decorated sheet so that the first and second fiber reinforced resin layers can join one another to form a continuous consolidated strip of fiber reinforced resin with an image suspended therein, curing the continuous consolidated strip, and cutting a panel from the continuous consolidated strip. The first fiber reinforced resin layer is preferably at least partially cured in a first curing step before the second fiber reinforced resin layer is formed.

Abstract: An in-mold and in-line decorating method is disclosed which, using a single sheet layer, allows the placement of the highest possible quality graphics into the surface of products made from a variety of moldable thermoplastic, thermoset, and vulcanizable materials using a variety of molding processes. The methods also provide new or improved capabilities for product identification, safety, and serialized tracking.

Abstract: A method (110) of manufacturing footprint tiles (10) having the steps of: rolling (112) tile base (12) to a predetermined uniform thickness; imprinting (114) by utilizing a plate or roller with a plurality of convex footprints and exerting pressure upon the rolled tile base (12) forming a plurality of concave footprint impressions (14) into the tile base (12); cutting (116) by utilizing a plate or roller with a plurality of blades complementarity positioned to the plurality of concave footprint impressions (14) and exerting pressure upon the rolled tile base (12) forming individual foot print tiles (10); and drying (120) the individual foot print tiles (10).

Abstract: A process is proposed for the fabrication of parts with large dimensions formed of a skin (10) and stiffeners (12, 16) such as aircraft fuselage segments made of a composite material with a thermoplastic matrix. After stiffeners have been made separately by lay-up, consolidation and shaping, these stiffeners are placed on a tooling (23) and the skin (10) is simultaneously fabricated and assembled to the stiffeners (12, 16) by diffusion welding. More precisely, the skin (10) is laid up and continuously consolidated by the lay-up head (36) such that the required part is obtained directly.

Abstract: A surface treating article including a surface treating member and a fastener including a fiducial. The present invention also provides a preferred method of making a surface treating article that includes to a method of sensing the location of a fasteners on a surface treating web and thereafter cutting the surface treating web around the fastener to provide a surface treating article.

Abstract: A method for manufacturing a substrate strap for electrical elements has arts of preparing materials, mixing the materials with a mixer, pressing the mixed materials to a strap with a desired thickness, roller pressing the strap at a high temperature to a precious thickness, roller pressing the strap at a low temperature to set and defining holes in the strap with a punching machine. Accordingly, the molecules of the uncrystallized material can be connected between the crystals of the crystallized material so as to form multiple fibers in the strap, such that the substrate strap has an excellent structural strength.

Abstract: Method for producing decorative grass, such as Easter grass, from a sheet or web of material having printed material and/or embossed patterns thereon. The printed material and embossed patterns may be in register or out of register with one another. A method for producing decorative grass having the appearance of a blend of decorative grasses is also disclosed.

Abstract: A production line including a molding press for molding a resin on a strand of material and a cutting press for cutting parts from the strand. The production line feeds the strand at a uniform rate without slack. The cutting press includes a die that moves toward and away from the strand. The die moves transversely to the strand to transport cut parts.

Abstract: A tie bag having improved tie features is provided by increasing the thickness of the tie features as compared to the bag thickness.

Abstract: A method is provided for making ligneous material boards into an endless board strand with a continuously operating press. The press includes two flexible endless steel belts which take the press material between them and carry it through the press. The steel belts thrust with friction-reducing elements against heated press plates of the press table and press ram and a cooling system that follows. The cooling system is configured as a double-belt holding apparatus with an applicable holding pressure up to a maximum of 0 to 0.05 N/mm2. A diagonal sawing apparatus, which is disposed directly behind the continuously operating press and ahead of the cooling system, divides the board strand into single boards. Several rows of coolant spray nozzles disposed on the backs of the holding belts making contact with the single boards.

Abstract: A method for formation of shaped components such as shaped absorbent cores, for disposable absorbent articles, contemplates that a relatively wide web of material be provided from which the components are cut. The web of material is longitudinally slit to form a plurality of subdivided webs each having shaped components arranged in serial relationship. The shaped components of adjacent ones of the subdivided webs are nested with each other, that is, a line extending longitudinally of the web extends through the components of adjacent subdivided webs. Efficient formation is facilitated by collecting the marginal portions of the web of material, and at least partially recycling the collected portions for formation of the wide web.

Abstract: The tape is free from any slack and separation even when it is applied and bonded to a metal joint portion while being bent. The tape, made of an unvulcanized material containing an unvulcanized rubber-base material, a vulcanization accelerator, an anti-oxidizing agent, a pigment and a bulk filler, is formed into an elongated shape having an upper and a lower surface and a predetermined thickness measured in a direction perpendicular to the lower surface or flat bottom surface 1. The upper surface forms a circularly-curved surface 2 in cross section. Since the tape is in an unvulcanized state, it is capable of being free bent when applied to the metal joint portion. After application of the tape to the metal joint portion, a paint is applied to the tape, which is followed by a heating process in which the tape is heated, and, therefore vulcanized.

Abstract: An apparatus for continuously shaping a compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from a surface of a slab of the material includes a compression roller, a support surface, a blade and a moving patterned platform interposed between the compression roller and the support surface. The moving patterned platform, preferably an endless belt or a series of interconnected panels, defines at least one recess, and may define a pattern of recesses of complex or simple shapes and at various depths. When the slab of cellular polymer material is compressed between the compression roller and the support surface, a portion of the material fills the recess or recesses in the moving patterned belt. The blade then transversely cuts from the surface of the slab a portion of the material within the recesses in the platform just as the slab emerges from between the compression roller and the support surface.

Abstract: Method for producing decorative grass, such as Easter grass, from a sheet or web of material having printed material and/or embossed patterns thereon. The printed material and embossed patterns may be in register or out of register with one another. A method for producing decorative grass having the appearance of a blend of decorative grasses is also disclosed.

Abstract: A non-woven fiber pad having a convoluted surface formed by cutting a non-woven fiber batt having a plurality of low melt synthetic fibers. The non-woven batt is compressed generally toward a cutting device by a pair of counter-rotating drums having convoluted surfaces.

Abstract: The present invention relates to a power transmission striated belt including an elastomeric matrix (21) and a lengthwise supporting structure consisting of polyamide 4.6 twisted strands (20). The supporting structure (21) is selected so that the stress-elongation diagram of the belt exhibits an average slope ranging from 12 to 20 daN/% of elongation per width centimeter. The twisted strands are wound with an almost null nominal tension, and the curing operation and the cooling operation after curing are carried out without any belt tensioning.

Abstract: A trim press article handling apparatus includes a punch plate, a die plate, a plunger, and a receiver. The punch plate has a punch, and the die plate has a die cooperating in relative movement with the punch plate to sever articles from a thermoformable web. The plunger is carried by one of the punch plate and the die plate having a tapered advancing head. The receiver is carried by the other of the punch plate and the die plate having a tapered recess configured to receive the plunger. A tapered article locator provided within a thermoformed web also having articles therein is captured between the plunger and the receiver as the punch plate and die plate are brought together there about, thereby imparting alignment of an article in the web between the punch and the die. A method for aligning and severing articles from a web is also provided.

Abstract: A trim press article handling apparatus includes a punch plate, a die plate, a plunger, and a receiver. The punch plate has a punch, and the die plate has a die cooperating in relative movement with the punch plate to sever articles from a thermoformable web. The plunger is carried by one of the punch plate and the die plate having a tapered advancing head. The receiver is carried by the other of the punch plate and the die plate having a tapered recess configured to receive the plunger. A tapered article locator provided within a thermoformed web also having articles therein is captured between the plunger and the receiver as the punch plate and die plate are brought together there about, thereby imparting alignment of an article in the web between the punch and the die. A method for aligning and severing articles from a web is also provided.

Abstract: Film treatment surface provided with a propulsion system for circularly contoured film (5) along a circular path are disclosed. The essential propulsion and steering system is represented by two adjustable disks (2, 3), one being equipped with a propulsion wheel and a steering mechanism whereas the second disk embodies an idler wheel and a steering mechanism. The treatment surface was found to be beneficially suitable for the manufacture of cut shaped blanks made from shaped films of plasticized polyvinyl butyral. The blanks can be used in automobile windshields.

Abstract: The present invention is directed toward a filter media for a high efficiency particulate air (“HEPA”) filter including a multiplicity of adjacent electrostatically charged piles of nonwoven fabric. The invention further includes a method of making a HEPA filter.

Abstract: A system for making wallboard or backerboard sheets may include a mixer for mixing materials for making aerated concrete, at least one face layer supply, and a former downstream from the mixer. The former is for forming core material having opposing first and second major surfaces and comprising aerated concrete, and for securing at least one face layer from the at least one face layer supply onto at least one of the first and second major surfaces of the core material. The system may also include a cutter downstream from the former for cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example.

Abstract: A method for making wallboard or backerboard sheets which are relatively lightweight, strong, and which have good fire resistance, thermal insulation, and sound absorbing properties includes forming core material having opposing first and second major surfaces and comprising aerated concrete, securing at least one face layer on at least one of the first and second major surfaces of the core material, and cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example. In one class of embodiments, the method may further include curing the core material prior to securing the at least one face layer thereto. In another class, the method may further include curing the core material after securing the at least one face layer thereto.

Abstract: A thermoformer, which produces zero scrap during the heating, forming and cutting of a blister package uses a precut roll having a series of adjacent webs connected by a cut area. Each of the webs are defined by an overall length L, a width W, and a radius R. Each of the cut areas are defined by a cut depth D1, said cut depth D1 being in the range of about 25% to 90% of the width W of the webs. The thermoformer further comprises a heating station adapted to heat each of the webs, a forming station adapted to form each of the webs, and a cutting station adapted to separate the webs from each other, by making a cut along each of the cut areas connecting the webs.

Abstract: A method for manufacturing composite parts includes positioning a plurality of composite layers on an application surface formed by a plurality of tooling members and filler members on a mandrel. A part formation aid is disposed on the composite layers above each tooling member. The filler members are then removed, and the composite layers slit over the recesses. The mandrel, the tooling members, the composite layers, and the part formation aids are placed in a vacuum bag. As the bag is evacuated, each part formation aid forces the side edge of the composite layers formed by the slit around the respective tooling member, thereby forming a composite part with a desired shape, thickness, and density. In an alternate embodiment, a flanged composite panel is formed around a rectangular mandrel after positioning composite layers on an outer surface of the mandrel and an outer surface of a filler member disposed on one end of the mandrel.

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 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: The present invention relates to a process of forming a multi-layer pad of a non-woven fiber batt and a foam layer having conforming convoluted surfaces and to a multi-layer pad incorporating a non-woven fiber batt and foam layer. The process of forming a non-woven batt layer and a foam layer having conforming convoluted surfaces comprises transporting each layer along its longitudinal dimension while compressing each layer along its lateral dimension. Concomitantly with compression, each layer is cut transversely along its lateral dimension to separate each layer into an upper segment and a lower segment and to provide conforming convoluted surfaces on the segments of each layer, the convoluted surfaces comprised of upstanding projections and depressions.

Abstract: A molded article such as a floor tile is made from recycled carpet waste which includes a polyvinyl chloride component in the backing material and fiber component having a melting point above the melting point of polyvinyl chloride. A mixture of the recycled carpet material is shredded and additional polyvinyl chloride is fed to an extruder where the polyvinyl chloride is melted without melting the carpet fibers. The resulting mixture is discharged and molded, such as by injection molding, to form a molded product. The molded product includes a continuous matrix of polyvinyl chloride having recycled carpet fibers uniformly dispersed therein. The molded article contains about 45% to about 85% of polyvinyl chloride, about 5% to about 20% of recycled carpet fibers, up to about 5% of a plasticizer and up to about 5% of an ethylene copolymer by weight based on the total weight of the product.