Abstract: The invention relates to a novel, innovative industrial method for producing polystyrene (EPS) foam parts of arbitrary length and having a constant cross-section, with mixed densities located in accordance with the mechanical and thermal properties required for each application. The invention also relates to a machine (apparatus) for producing said solid parts having localized densities defined by the mechanical and thermal requirements of the application. The aforementioned products are produced by joined both longitudinally and transversely. The invention can be used to reduce the standard method to three steps, thereby resulting in a significant saving in terms of production. Moreover, unlike with the standard method, variants can be produced using the above-mentioned method, thereby increasing the range of application said type of products.

Abstract: It is an object to prevent dies from interfering with each other when the dies are closed and effectively prevent overshoot of cavity temperature while efficiently performing heating of the dies. In an injection molding machine for two-material molding including two sets of a first injecting unit and a second injecting unit that respectively plasticize different resin materials and inject and fill the resin materials, prior to performing injection molding on the first injecting unit side on a secondary side, after injection molding on the second injecting unit side on a primary side, heating of the dies is started before 180-degree rotation of a rotary die plate is completed. After the start of heating, until the 180-degree rotation of the rotary die plate is completed, i.e., die closing is performed, die temperatures are maintained within a temperature range set higher than die temperatures during the heating start and lower than die temperatures during injection.

Abstract: An apparatus for cushioning and protecting body parts of a human or animal is described. The apparatus includes a blend of dual durometer resilient flexible materials with a plurality of degrees of hardness to personalize the properties of comfort, proper fit, structure, and protection. The resilient flexible materials comprise thermoplastic, thermoset, casting, curing, epoxy, or resin materials, and a soft part is customizable.

Abstract: A gas turbine engine includes a fan including a plurality of circumferentially spaced rotatable blades, and a fan casing for containing fragments of fan blades in the event of blade release, the fan casing having a shell surrounding the blades and circumscribing a containment zone of the fan. The shell is made of a fiber reinforced polymer composite material which includes nanoparticles.

Abstract: A method of forming an article of footwear includes injecting a first material into a first cavity of a mold assembly to form a sole assembly, injecting a second material into a second cavity of the mold assembly, a first last being suspended within the second cavity, to form an upper of the article of footwear about the first last. The upper and the sole assembly are positioned in contact with one another. The upper and the sole assembly are cured and bonded together to form an article of footwear. The article of footwear is removed from the mold assembly and from the first last and allowed to expand to a first size. The article of footwear is placed on a second last having a second size that is smaller than the first size, and heated and cooled until it shrinks to the second size.

Abstract: A large area patterned film includes a first patterned area; a second patterned area; and a seam joining the first patterned area and the second patterned area, wherein the seam has a width less than about 20 micrometers. A method for tiling patterned areas includes depositing a predetermined thickness of a curable material; contacting a first portion of the curable material with a mold; curing the first portion of the curable material; removing the mold from the cured first portion of the curable material; contacting a second portion of the curable material with the mold, such that the mold contacts a portion of the cured first portion of the curable material; curing the second portion of the curable material; and removing the mold to yield a seam between the cured first portion of the curable material and the cured second portion of the curable material, wherein the seam has a dimension less than about 20 micrometers.

Abstract: Techniques for component protective overmolding using protective external coatings include selectively applying a protective material substantially over one or more elements coupled to a framework configured to be worn, the elements including at least a sensor, and forming one or more moldings substantially over a subset or all of the framework, the protective material and the elements, after the protective material has been selectively applied, at least one of the one or more moldings having a protective property.

Abstract: A method of insert molding comprises placing in a first mold a curable rubber composition comprising a reactive species; placing on a surface of the rubber composition a first thermoplastic material in a film or layer comprising a group reactive with the reactive species of the rubber composition; curing the rubber composition in the mold to form a first molded article of cured rubber having a first thermoplastic material layer covalently bonded through reactive of the reactive species and the group; placing the first molded article as an insert into a second mold, the cured rubber contacting an inside surface of the second mold and the thermoplastic layer facing into the second mold cavity; closing the second mold and injecting into the second mold a second thermoplastic material that to form a second molded article comprising the first molded article thermally welded and/or covalently bonded to the second thermoplastic material.

Abstract: A protective helmet includes an outer shell having a generally dome-shaped section and a brim extending outwardly from the dome-shaped section. The dome-shaped section and the brim are formed from a thermoplastic material. The helmet further includes a brim support in operative connection with at least a portion of the brim. The brim support is formed from a material that is more heat resistant than the thermoplastic material. The brim support is sufficiently rigid to limit deformation of the brim upon exposure to high temperature. The brim support material can, for example, have a melting point above 500° F. A method of limiting high-temperature deformation in a helmet includes molding an outer shell of the helmet to consist essentially of thermoplastic material, the outer shell comprising a generally dome-shaped portion and a brim extending outwardly from the dome-shaped section by at least 2.

Abstract: A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament.

Abstract: An artificial feather for a shuttlecock including a vane portion in a thin film form, corresponding to a vane, and a rachis portion in a bar form extending integrally and continuously from an upper tip end to a lower distal end, corresponding to a rachis, to imitate a natural feather, the vane portion being made of thermoplastic resin having interconnecting bubbles therein, and having low specific gravity and low elasticity relative to the rachis portion, the rachis portion being made of thermoplastic resin being fixed to the vane portion at a vane support portion, having the vane support portion set as an area that is fixed to the vane portion along the tip end to a bottom end of the vane portion, and having a calamus portion set as an area that protrudes to a lower side of the vane portion and spans from a bottom end of the vane support portion to the distal end, to correspond to a calamus of the natural feather.

Abstract: A method for producing a multilayered moulding (2), in particular a panelling element for a motor vehicle, forms an intermediate layer at least in some parts between a substrate layer (6) and a decorative layer (7). In this case the substrate layer (6) and the decorative layer (7) are arranged in a mould cavity (5) of a die (1), wherein at least in some sections between the substrate layer (6) and the decorative layer (7) at least one hollow cavity (9) is formed. After this the intermediate layer (8) is formed in the hollow cavity (9).

Abstract: A method of making an injection molded device includes the steps of (a) assembling a mold comprising a primary male mold half and a primary female mold half to define a primary mold cavity; (b) injecting a first fluid polymeric material into the primary mold cavity and permitting the first fluid polymeric material to solidify to form a device frame; (c) replacing the primary female mold half with a secondary female mold half; (d) restraining the device frame in the resulting mold cavity and injecting a second fluid polymeric material to form a first portion of an outer layer that retains the shape of the first overmold cavity; (e) replacing the primary male mold half with a secondary male mold half; and (f) injecting an additional amount of the second fluid polymeric material into the resulting cavity to form a sufficiently integral outer layer about the device frame.

Abstract: A method of making a hand guard for a semi-automatic or automatic rifle is provided. The method including the steps of: forming a first portion of the hand guard from a first material; inserting the formed first portion into a mold; and molding a second portion of the hand guard about the first portion, the second portion being a second material, the second material being different from the first material, wherein a first section of the first portion is completely encased by the second portion and a second section of the first portion is not encased by the second portion.

Abstract: The invention relates to an application unit for a cosmetic product for an applicator comprising a region for receiving the application unit, the said application unit comprising: a support comprising a first portion suitable for the fixing in removable fashion of the support to the reception region and a second portion forming at least one compartment for receiving the cosmetic composition, at least one cosmetic product to be applied to human keratinous substances, the composition of the product being different from that of the material forming the support. According to the invention, the cosmetic product is moulded by injection onto the support. The invention also relates to a process for producing an application unit.

Abstract: A fan member particularly for use in a vehicle cooling system. A formed metal hub member with a plurality of plastic polymer blade members. The blade members are overmolded on the hub member, preferably individually. The plastic polymer material is molded through openings in the hub member to help securely hold the blade members in place.

Abstract: A molded game ball and process for making the same. The game ball comprises a molded outer cover having a mold line that mimics the seam of a conventional game ball and a raised stitch pattern presented along said mold line. The game ball is made by forming an outer cover in a mold that has a pattern that is positioned to mimic the inverse of the pattern of a seam of a conventional game ball. Material is then injected into an interior volume enclosed by the outer cover to form an inner core that permanently bonds with the outer cover. The outer cover of the game ball has a stitch pattern that mimics the stitching and seam of a conventional stitched game ball.

Abstract: Disclosed herein are compositions comprising an oblong optode sensing agent. The oblong optode sensing agent comprises a core and a semipermeable membrane, wherein the core comprises one or more sensors configured to bind to an analyte. In addition, methods of making and detecting the oblong optode sensing agents are disclosed.

Abstract: A method for producing a flexible, three-dimensional coating structure with a surface curvature on the front side and an impression on the rear side for a flexible switch or a flexible user interface. The method is essentially characterized by the following steps: introducing an uncured, transparent casting compound into a compression mold with an impression that forms the shaping of a surface curvature; introducing a counterpunch that penetrates at least partially into the impression, so that the casting compound is distributed in the gap between the shaping of the surface curvature of the compression mold and the surface of the counterpunch and fills this gap; introducing energy into the casting compound, so that the casting compound cures to form a substantially self-supporting, flexible, transparent surface layer with a surface curvature on the front side and an impression on the rear side.

Abstract: An improved chair back is formed of a molded construction uses multiple mold shots of mold materials to develop different performance characteristics in selected areas of the chair back. The chair back has the appearance of a unitary molded panel, but is formed from multiple mold shots which preferably are performed at multiple stations on a mold tool. By providing multiple mold shots and selected materials to form different areas of the chair back, different performance characteristics are generated including the provision of a peripheral frame providing structural rigidity to the chair back, a lumbar support panel which provides localized support to the lumbar region of the chair occupant, and a thin sheet-like support panel extending between the frame and enclosing the interior region defined between the peripheral frame to provide a more flexible and pliant surface providing more comfortable contact with the occupant's back.

Abstract: According to one embodiment, a manufacturing method includes performing lithography processes for manufacturing a semiconductor device that includes a three-dimensional stacked device. The stacked device includes layers stacked above a substrate. Each of the layers includes a device circuit. The lithography processes include a lithography process for forming a lower layer of the layers by using a first original plate that has quality not less than a certain level. The first original plate is selected from original plates. Each of the original plates includes a pattern corresponding to the device circuit. The original plates are ranked according to quality based on defect. The lithography processes further include a lithography process for forming a higher layer of the layers by using a second original plate that has quality lower than the certain level. The second original plate is selected from the original plates.

Abstract: A method of making a golf ball may include molding at least one core layer and molding an outer cover layer radially outward of the at least one core layer, from an outer cover layer material, including forming one or more grooves extending radially inward from an outer surface of the outer cover layer. The method may also include molding a groove material within the one or more grooves, the groove material having a compressibility that is different from a compressibility of the outer cover layer material. In addition, molding the groove material may include forming the groove material such that an outer surface of the groove material extends radially outward beyond the outer surface of the outer cover layer.

Abstract: A plastic product having a hard plastic component and a soft plastic component that adheres to the hard plastic component via at least one boundary surface is produced as follows: initially the soft component is injection molded in an injection molding die. Then the hard component is injection molded. In the plastic product produced in this manner, the soft component is surrounded over at least part of the circumference thereof by the hard component in the circumferential direction about a main demolding direction of the injection molding die. The result is a plastic product, wherein the shape and arrangement of the soft component can be tailored to functional requirements more flexibly.

Abstract: The invention concerns a device for injection molding (1) comprising a first fixed half-mold (3) and a second half-mold (5) mobile in direction (y) of the side blocks (4) of an injection molding machine (2). Between the first and the second half-molds are mounted first and second immediate elements (6, 7) mobile in the direction of the side blocks (4). The first and the second intermediate elements (6, 7) comprise each a mold support (12, 13) pivoting relative to a base (14, 15, 31, 32) about a pivoting axis (8, 9). Centering elements (26, 27) upon the opening and closure of the injection molding devices (1).

Abstract: A method for forming an end cap includes cleaning an exposed end of a conduit upon which the end cap will be formed, inserting a backing material into the exposed end of the conduit to the desired resin depth, dispensing the resin into the conduit, spreading the resin across the backing material, curing the resin with a radiation source and applying additional layers of resin and curing until the resin is flush with or forms a convex surface relative to an exposed end of the conduit.

Abstract: A co-molding process includes molding a body between a “common cavity” and “first shot core” die halves, co-molding a soft plastic onto the first component to form a final part using the “common cavity” die half and a “second shot core” die half. The “second shot core” die half includes shallow formations forming expansion locks along an elongated edge of the final part on a non-show concave surface, the locks having a shallow depth and extending in a direction non-parallel a die pull direction such that the locks affirmatively prevent shifting of first component during the co-molding process. Also, the locks can be made to cause the final part to remain with the “second shot core” die half when dies are opened during a final step of the co-molding process.

Abstract: A plastics preform for an inflatable large-volume container, in particular for a container with capacity of at least 5 liters, preferably at least 10 liters, has a closure region and an inflatable hollow body region. For reducing cycle time, the preform, or at least the inflatable hollow body region thereof, is composed of a plurality of layers, where the thickness of each layer is at least 2 mm, preferably at least 3 mm, and where the thickness of the individual layers is in essence identical. Multicomponent injection moulding technology can thus be used with the rotating table technique or with the indexing plate technique to produce the various layers simultaneously in a plurality of injection units in such a way as to give, after each shot, a finished thick-walled preform. Also described are a process for producing the plastics preform and an injection moulding machine.

Abstract: Methods and tools for producing a filled hollow structure, comprising producing an open hollow structure from a first material, providing a closing structure to at least partially close the open hollow structure, filling the hollow structure with a filler medium, and overmoulding the filled hollow structure with a second material as well as hollow structures obtainable by said methods and the use of said tools.

Abstract: Disclosed are a battery pack and a method of manufacturing the same, in which a case accommodating a core pack including a bare cell and a protection circuit member is integrally formed as a single body by using a foam, thereby improving impact resistance of the core pack and improving working efficiency and productivity without the need of an adhesive coating step. The battery pack includes a core pack including a bare cell and a protection circuit member attached to one side of the bare cell, a case formed of a foam and accommodating the core pack, and a shielding layer formed on a surface of the protection circuit member.

Abstract: An apparatus for manufacturing infiltrating water-proof material for zippers comprising a lower mold and an upper mold, wherein the lower mold is positioned with a positioning recession and a groove, the upper mold is provided with a mold cave on a top thereof and a scraper portion on a bottom edge thereof and adhering to a bottom surface of the positioning recession, whereby the upper mold is assembled to the lower mold into a unitary member in which the upper mold is fitted in the positioning recession, a liquid PU rubber which has been treated with thickening step is poured into the mold cave of the upper mold, and then a zipper tap is moved by transferring rollers to the positioning recession to provide a water-proof film therefor.

Abstract: The present invention refers to a method and to a device fro producing a molded port having a plurality of different decorative regions that abut each other, wherein the different decorative films (9, 10) are inserted into a molding tool (1) by a gripper (4). There they are fixed be means of sliders (8) and are then back molded with a thermoplastic material.

Abstract: The present invention is related to a method for testing multilayer tablets in a multiple rotary press, in which die holes of a circulating die plate are successively filled with tablet material of different layers in succeeding filling devices, and the tablet material is compressed one layer after the foregoing layer into pressed articles having n layers by means of synchronously circulating compression punches, and the pressed articles are subsequently ejected in an unloading station and taken out, in which in a testing procedure, pressed articles with m layers are taken out after the compression in a respective unloading station and are conveyed to a testing station, wherein applies 1<=m<=n, wherein before taking out the pressed articles, at least the m-th layer is compressed more strongly than during the normal manufacture of the multilayer tablets, wherein applies m<n.

Abstract: A method of making a vehicle headrest restraint and connecting first and second molds to form a mold cavity. A first material is injected with a first density into the mold cavity. A second material is injected with a second density into the mold cavity. The first and second materials are cooled to develop an integrally formed headrest.

Abstract: A dispensing device for dispensing a liquid product from a container containing said product comprises a first chamber and a second chamber. An inlet passage comprising at least one inlet opening establishes a fluid connection between the first chamber and an interior part of a container having the dispensing device mounted thereon. An outlet passage adapted to deliver liquid product being dispensed by way of the dispensing device is fluidly connected to the second chamber. An intermediate wall divides an interior part of the dispensing device into the first chamber and the second chamber. The intermediate wall defines an edge, and the intermediate wall is arranged in such a manner that an intermediate passage between the first chamber and the second chamber is defined at said edge.

Abstract: A composite wafer carrier according to an embodiment of the present invention comprises an operative portion formed of a first thermoplastic material and a support portion formed of a second different thermoplastic material. One of the operative portion and support portion is overmolded onto the other to form a gapless hermitic interface that securely bonds the portions together. The operative portion may be a transparent window, a portion of a latching mechanism or a wafer contact portion. Preferred embodiments of the invention include wafer carriers with said features, process carriers with said features and a process for manufacturing wafer carriers with said features.

Abstract: A dispensing closure that comprises a pliable sealing surface that is selectively formed with a dispensing opening or a cleanout. At least a portion of the pliable sealing surface can be formed at a base of a skirt, wherein the skirt engages the dispensing closure with the container. Material of the pliable sealing surface can be bonded with material of a body portion and a flap portion of the dispensing closure during a multi-shot injection molding process. The pliable sealing surface can be formed from a thermoplastic elastomer and the body portion and flap portion can be formed from a polymer material.

Abstract: Apparatuses, systems, and methods for surface modification of catheters. The surface modification can be localized to a lumen surface of the catheter. The surface modification to the lumen surface extends radially into the catheter body a predetermined distance to provide a hardened zone having a hardness that is greater than a hardness of an exterior surface of the catheter body.

Abstract: A preventative maintenance method of strengthening the connection between high pressure, in situ piping. An encapsulation mold is installed over a properly functioning, non-leaking coupling or joint interconnecting pipe sections carrying gas in excess of 60 psi. A resin sealant having tensile strength in excess of 3000 psi fills the mold, so that it circumscribes the coupling and adjacent portions of the pipe sections extending from the coupling, forming a permanent bond to the coupling and pipe sections. The method prevents high pressure pipe connection pullout, which otherwise could lead to catastrophic failure.

Abstract: A method for manufacturing a grating safety cover includes forming a perforated plate through which a plurality of holes vertically pass, inserting, respectively into the holes, half-conical pillars each having a smaller diameter than that of each of the holes such that the outer circumferential surfaces of the half-conical pillars are separated from the inner circumferential surfaces of the holes, forming an upper layer by applying an elastic material onto the perforated plate in which the half-conical pillars are inserted, and separating the half-conical pillars. According to the grating safety cover, drainage is well performed and a heel, a stroller wheel, or the like is prevented from easily falling into the safety grating. Further, due to shock absorption of the elastic layer, the safety grating has excellent durability and is not easily damaged.

Abstract: Procedure for the manufacture of a tube made of a flexible material and comprising a skirt and a head, in which a unit formed by the skirt and an appendage is disposed or manufactured in an injection procedure, the appendage totally or partially closing one end of the skirt and including the injection point(s), in which the appendage is cut totally or partially, and the cut part is removed, and in which the head over-molded on any area of the part of the unit formed by the skirt and appendage that remains once the cut part has been removed. The appendage offers several advantages, such as improving the finish of the over-molded head or, in the event of the unit being manufactured, easing the removal of the unit from the mound.

Abstract: The present invention provides entirely or partially injection-moulded multi-component composite systems having improved fire behaviour and a process for their production.

Abstract: A vehicle cowl component configured to extend between a hood's rear edge and a vehicle front windshield comprises a cowl and a seal, the seal including a U-shaped cross section attached to the under-hood edge and having upwardly extending front and rear curved walls, each of the curved walls having an unconnected free end. In one embodiment, the seal is two-shot molded onto the cowl, which eliminates secondary attachment operations. A method includes steps of first-shot molding a cowl, and then second-shot molding a U-shaped seal onto the cowl along an under-hood front edge. A modified cowl includes a seal with a downwardly extending wiper for sealing engagement with a body support structure under the cowl and seal.

Abstract: A method for fabricating a grid-stiffened structure from fiber-reinforced composite materials. A skin is applied to a smooth, hard base tool. Ribs comprised of carbon-fiber tows are formed on the skin, and shallow cavities are formed between the ribs and the skin. An expansion block is placed in each of the cavities, and is held in place by an elastomeric contact adhesive having adhesive properties that are substantially diminished when the adhesive is heated to an elevated curing temperature. The assembly is then autoclave cured. After cooling, the formed structure is separated from the base tool and the expansion blocks are removed from the cavities. A grid-stiffened sandwich structure is formed by applying an outer skin over the ribs and expansion blocks, before curing the assembly. After cooling, the outer skin is removed to allow extraction of the blocks, and subsequently bonded to the ribs.

Abstract: A method of manufacturing a condom having an open end and a closed end, wherein the method is comprised of the steps of coating a bare mandrel with a pattern of coating material to form visual stimulation means, and subsequently uniformly applying additional material over these patterns to complete the formation of the condom, and thereby create projections between the ends of the condom for stimulation.

Abstract: The invention provides a process for producing a moulding (10), in particular a motor vehicle moulding, a visible side (16) of the moulding (10) having a cover part (12) which is back injection moulded with a plastics material (14), and a film (26) being arranged between the cover part (12) and the back injection moulded plastics material (14), wherein the process comprises the following steps: production of at least one recess (22) in the cover part (12), application of the film (26) onto the cover part (12) so that the film (26) covers the at least one recess (22) in the cover part (12), and back injection moulding of the film (26) with the plastics material (14).

Abstract: A process is disclosed for forming a brim-mount ring included in a container lid.

Abstract: A modular plastic floor tile is formed by molding a body of a first polymer compound and overmolding features onto the body from a second polymer compound. The compounds may be different from each other in hardness and/or color. The overmolded features may include skins on the sides and bottoms of support member cores disposed below the tile lower surface.

Abstract: A plastic floor tile is formed by molding a body of a first polymer compound and overmolding features onto the body from a second polymer compound. The compounds may be different from each other in hardness and/or color. The overmolded features may include raised pads on the upper surface of the tile. The pads on the upper surface may be injection-molded from the lower surface through through-holes, which are smaller in area than the area of the pads.

Abstract: In a method of making multi-component plastic molded parts, using an apparatus which includes two outer platens with first half-molds, and a middle platen with second half-molds interacting with the first half-molds such as to define cavities in two parting planes for injection of a plastic melt and/or a PUR mixture, one of the first and second half-molds can move in increments relative to the other one of the first and second half-molds, thereby forming different cavities in the parting planes from cycle to cycle. In a first cycle preforms are produced in respective cavities and then held in one of the first and second half-molds as the other one of the first and second half-molds moves in increments. Further components can then be injected into cavities formed in the parting planes from cycle to cycle, while another process step can be executed from cycle to cycle in free half-molds.

Abstract: Improved techniques are disclosed for housing electronic components. A first housing member can be made to have an exterior surface that covers a majority of the housing. The first housing member can be of unitary construction. The first housing member can be seamlessly constructed. The first housing member can be formed in one injection molding. An electrical power conduction pin can extend through an aperture in a cover plate, and can be arranged for mechanically coupling the cover plate with a major interior surface of the first housing member, so as to secure the cover plate to the first housing member.