Abstract: Methods and apparatus for filling form gaps are disclosed. In one embodiment, a method includes providing a heating and pressurizing dispenser for thermoplastic, heating and pressurizing a thermoplastic in the dispenser, discharging the thermoplastic through a nozzle attached to the dispenser and filling the gap in a form with the discharging thermoplastic from the nozzle. In other aspects of the invention, the thermoplastic includes polypropylene with talc. In another aspect of the invention, a composite product is produced by providing a form, and filling the gaps in the form with thermoplastic, and forming the composite product against the form. In yet another aspect to the invention, a high temperature and high pressure dispenser for filling gaps in forms is provided.

Abstract: A battery pack includes: a battery including a battery element covered with a packaging member, the battery element including a positive electrode and a negative electrode which are spirally wound together or stacked on one another through a separator; a protection circuit board for the battery; and a covering material collectively covering the battery and the protection circuit board. The covering material includes a shape-retaining polymer. The shape-retaining polymer contains an insulating curable polyurethane resin including polyol and polyisocyanate.

Abstract: The invention concerns a method for covering parts of a rail (1) for railway vehicles which are not in contact with the vehicle wheels, said method comprising applying a rubber jacket (6) on said parts and fixing said jacket to the rail, said jacket having outer lateral sides which extend along the rail, and for a predetermined load exerted by the vehicle on the rail, a distribution of said load between a first fraction exerted on the rail head (3) and a second fraction of said load exerted on the rail base (4) is determined, the geometry of each lateral side being configured to form a non-rectilinear profile allowing said distribution between said first and second fraction.

Abstract: A plastic card, including a bottom overlay, a top overlay positioned above a top surface of the bottom overlay and a core layer positioned between the top surface of the bottom overlay and the top overlay. A method for manufacturing a plastic card, including loading a bottom overlay into an injection molding apparatus, loading a top overlay into the injection molding apparatus wherein the top overlay is positioned above a top surface of the bottom overlay and injecting a core layer between the bottom overlay and top overlay, wherein one or more protrusions are formed on the surface of the top overlay. The protrusions may be arranged in such a way as to form designs on the surface of the plastic card.

Abstract: An apparatus for generating electrical energy includes at least one generator connected to a drive device. The drive device includes at least one guide element for transforming the energy of a flowing medium into a rotational movement. The guide element is arranged in the flow path of the heated exhaust air coming from at least one heat exchanger.

Abstract: A method of manufacturing decorative plastic composites having a decorative layer, a backing layer and a clear outer layer which provides exceptional “depth of image” is disclosed. Decorative or protective appliqués' having a wide range of decorative patterns may be formed by injection molding a backing layer behind and a clear outer layer on the top surface of a thin foil, film, fabric or veneer. A method is also disclosed for coating the exposed surface of the decorative layer between injection of the backing and outer layers to impart a desired visual effect or repair the surface. Use of multiple layers of decorative film, clear plastic and colored/opaque plastic is also disclosed to provide distinguishing visual effects.

Abstract: In a method of making a control arm for a wheel suspension of a motor vehicle a blank of steel material having a tensile strength of at least 800 MPa is shaped, using a sheet metal forming process, into a shell body having a center web and plural flank portions extending from the center web in a same direction. The flank portions are connected by a latticed reinforcement made of plastic, without application of a heat treatment process.

Abstract: An improved molding apparatus and method of use thereof that inhibits unsightly blemishes that may be formed in molded plastic parts in caused by confined crevices of the molding apparatus. A mold cavity is formed by at least two mold portions and one of said mold portions has a molten plastic flow diverter positioned adjacent the confined crevice. The charge of molten plastic is injected into said cavity such that a portion of the charge of plastic flows over the diverter and into the confined crevice of the mold cavity. The diverter creates a narrow restriction adjacent the crevice such that the mold cavity has a larger cross-sectional area on either side of the diverter.

Abstract: A method for manufacturing a battery pack is provided in which a cell 2 that includes a contact pad 9 attached thereto is placed on a die 24, and a cover that is integrated with the cell 2 and the contact pad 9 is molded. The contact pad 9 includes a body that includes an opening formed therein, and an external connection terminal disposed at the position of the opening. The cover is molded by bringing the surface of the body into contact with a die 26 and injecting a resin into a space surrounded by dies 24, 25, and 26 and the cell 2. The contact is a flat surface contact without fitting. Accordingly, resin leakage can be prevented with a simple structure in an integrally-molded type battery pack, and thus stable molding can be performed.

Abstract: A method for manufacturing a weighted mounting platform, the method including: of a first injection moldable material, injection molding a substantially rigid body structure further comprising a substantially central hub with a plurality of legs projecting therefrom and an enlarged mass positioned adjacent to an end portion of at least two or more of the plurality of legs distal from the hub; of a second injection moldable material, injection molding a flexible skin covering at least a portion of the body structure between each enlarged mass and the central hub; and subsequent to the injection molding a flexible skin, freeing the enlarged mass positioned adjacent to an end portion of at least two or more of the plurality of legs for motion relative to the central hub.

Abstract: The invention relates to an impact-absorbing element for a vehicle, in particular a car, comprising: a body comprising a thermoplastic polymer material; an elongate reinforcing structure provided in the body and comprising a number of metal reinforcing cords extending substantially parallel and a number of positioning elements arranged between the cords for holding the metal reinforcing cords substantially mutually parallel before and during the manufacturing process. The positioning elements ensure that the cords remain correctly positioned before, during and after the manufacturing process despite the forces occurring in the manufacturing process.

Abstract: Catheter (1) for vascular access comprising a cannula (2) having at least one first lumen (21), at least one first connection tube (3), and a connection molded simultaneously on an end of the cannula (2) and on at least one part of the first connection tube (3) and manufacturing process comprising the following stages: taking a cannula (2) having at least one first lumen (21), taking one first connection tube (3), placing in a mould one end of the cannula (2) and one end of the first connection tube (3), injecting into the mould a molding material to obtain the connection (4) between the end of the first connection tube (3) and the end of the cannula placing the first lumen (21) and at least the first tube (3) in fluid communication and device for implementing the manufacturing process.

Abstract: A method of manufacturing a resin molding according to the present invention is made by joining first and second resin molded parts. The method includes molding a concave portion when molding the first part, molding a convex portion which has a through-hole in a central portion thereof when molding the second part, mating the concave portion with the convex portion so that a cavity being in communication with one end of the through-hole is configured between the concave and convex portions, holding, with a jig, the first and second parts which the cavity is configured therebetween, connecting a tip of an injection nozzle for injecting a molten resin into the cavity with the other end of the through-hole, and filling the molten resin into the through-hole and the cavity from the injection nozzle so that the concave and convex portions are integrally joined by the resin.

Abstract: The present invention intends to provide a sealing structure of a terminal that is low in a processing temperature for sealing, easy in sealing operation and high in the productivity. In the invention, the thermal expansion coefficient of a sealing material is made equivalent to or more than the linear expansion coefficient of a metallic sealing case block by adding inorganic filler to a liquid thermosetting polymer.

Abstract: A soap device is provided. Such soap device includes a soap bar member manufactured from a first predetermined material and having a first predetermined size and a first predetermined shape. A depressed area is operably disposed in such soap bar member at a predetermined location thereon for receiving and housing at least one predetermined piece of soap. The depressed area has a second predetermined size and a second predetermined shape.

Abstract: A decorative architectural glass panel comprises a two or more glass sheets separated by a resin in which one or more decorative objects are suspended. A method of making the glass panel comprises positioning one or more spacers and one or more decorative objects on a first glass sheet, placing a second glass sheet about the first glass sheet, sealing the edges of the first glass sheet and second glass sheet, and filling the space between the first and second glass sheets with a curable liquid resin. The resin can be poured using a substantially horizontal pour in order to keep the decorative objects from substantially shifting when pouring the liquid resin. The resin can also be poured in combination with a vacuum force. In some implementations, the glass panel may also be substituted with a resin panel using polymeric resin sheets.

Abstract: The invention relates to a insulating concrete composition for producing, mainly, moulded building elements. The invention is a composition having a weight proportion of slag in the form of gravel and sand ranging from 40 to 80%, and a cement weight proportion ranging from 20 to 30%. The composition is used with water whose weight proportion ranges from 10 to 20% for obtaining a concrete. The invention also relates to an insulating building element which is made from the concrete and is used for producing a lost workform filled with concrete in order to build a carrying wall. After drying, the element forms an insulating coating for the carrying wall.

Abstract: In a process for the production of composite elements which have the following layer structure: (i) from 2 to 20 mm of metal, plastic or wood, (ii) from 10 to 300 mm of plastic and (iii) from 2 to 20 mm of metal, plastic or wood, the starting materials for the production of (ii) are introduced in the liquid state in at least two steps into the space between (i) and (iii), the space to be filled in the last filling process having a volume of from 0.1 to 1.5 m3 and the height of the space to be filled being less than 25 mm.

Abstract: A thermal spreading device disposable between electronic circuitry and a heat sink includes a substrate having parallel first and second faces and conduits extending through the substrate between the faces. The substrate material has a first thermal conductivity value in a direction parallel to the faces and a second thermal conductivity value in a direction normal to the faces, with the second thermal conductivity value being less than the first thermal conductivity value. The conduit material has a thermal conductivity value associated with it, with the thermal conductivity value being greater than the second thermal conductivity value of the substrate. One method of fabricating the thermal spreading device includes disposing a molding material radially about the rods and hardening the material. Other methods include press fitting and shrink fitting the rods into a substrate material.

Abstract: A method of bonding an insulation layer (26) to a CMC layer (22) by applying a compliant joining layer (24) between them in a series of steps (52-70) effective to bond the layers (22, 24, 26) with reduced differential shrinkage stresses during firing and reduced residual stresses. The CMC layer (22) and the compliant layer (24) may each be fired to an intermediate stage prior to applying the next layer (24 and 26 respectively), such that the compliant layer (24) has a remaining amount of curing shrinkage between that of the CMC layer (22) and the insulating layer (26) during a final firing stage. The insulation layer (26) may be a friable graded insulation (26F) cast as a composite of hollow ceramic spheres (26S) in a ceramic matrix (26M). The compliant layer (24) may form a checkerboard of cracks (72) oriented generally perpendicular to the layer surface that function to relax stress.

Abstract: A thermal interface material includes a macromolecular material having two opposite Surfaces, and a plurality of carbon nanotubes each having two opposite ends embedded in the macromolecular material. The two opposite ends of the carbon nanotubes extend out of the two opposite surfaces of the macromolecular material respectively. A method for manufacturing the thermal interface material is also provided.

Abstract: An interior article for automobiles is provided having a light-weight and suitable rigidity without lowering moldability even if the amount of use of a thermoplastic resin is decreased. A panel having a hollow double-wall structure and constituting an interior part for automobiles is formed from a mixture of polyolefin resins comprised of a propylene homopolymer having a specific gravity of 0.93 or less (JIS K7112), exhibiting a melt flow rate of 0.3 to 3.0 g/10 minutes (JIS K7210) and exhibiting a bending modulus of 1400 MPa or more (JIS K6758), a crystalline propylene block copolymer having a specific gravity of 0.93 or less (JIS K7112), exhibiting a melt flow rate of 0.3 to 1.5 g/10 minutes (JIS K7210) and exhibiting a bending modulus of 1250 MPa or less (JIS K7171) and a high density polyethylene having a specific gravity of 0.925 to 0.965 (JIS K7112) and exhibiting a melt flow rate of 0.5 g/10 minutes or less (JIS K7210).

Abstract: A method of manufacture of multilayer gypsum board, and a gypsum additive delivery system, including wet gypsum board passing through a board forming station in which additives are delivered to one or more layers of a multi layered gypsum board panels, such as engineered polymers, providing a better and more water resistance surface. Preferably, the gypsum board has a first layer of a mixture of set gypsum having an outer surface and a polymeric compound or wax emulsion additive entrained therein and impregnated in a thin sheet of randomly aligned inorganic fibers to essentially encase the core gypsum within two facing layers.

Abstract: The invention concerns an electronic data storage medium including a body (30) made from insulated plastic material which has two main parallel sides, a semiconductor component (34) and a number of external electrical contact pads flush with the first main side (30a) of the body. The body (30) includes a recess (32) opening out onto the first main side (30a). The storage medium also includes a number of conducting elements (28), each with a first end (a) flush with the first main side to form an external contact pad, a second end (b) arranged in the said recess and an intermediate part (c) buried in the body; and A number of connecting elements (38) to electrically connect the terminals of the semiconductor component to the second ends of the conducting elements.

Abstract: A kitchen whisk having a whisk-head attached to a grippable handle by a coupling, the handle having a flex zone for enhancing the “whipping” action of the whisk-head. A cable can be embedded within the flex zone region of the handle for reinforcing the same, the ends of the cable being disposed between and encased within a handle core and an inner plug core, the inner plug core being located within the coupling. In addition, the coupling captures the ends of the wires for attachment to the handle.

Abstract: There is disclosed a baffle for inhibiting the passage of sound, debris or the like through a cavity of an automotive vehicle.

Abstract: A dishwasher includes a washing container provided with a washing tub and a housing cover which is connected to the washing tub. The washing tub is provided with an inner tub and a plastic support in order to reduce the noise occurring when the washing liquid comes into contact with the washing tub.

Abstract: A method for encapsulating an area on a substrate comprising the steps of a) providing a substrate having an area on a surface thereof which is to be encapsulated, b) providing an assembly fixture which has features formed into the surface of the fixture, and vacuum orifices associated with the features of the fixture, c) positioning a substantially flat formable sheet onto the assembly fixture, and forming the sheet to the features of the assembly fixture by applying a negative pressure through the vacuum orifices, wherein corresponding features are formed in the sheet, d) patterning an adhesive onto the sheet or onto the substrate, the adhesive pattern corresponding to the perimeter of the area on the substrate to be encapsulated, e) clamping together the substrate and the sheet, causing the patterned adhesive to flow between the substrate and sheet in the area of compression, wherein the patterned adhesive is proximate to the features formed in the sheet, and f) curing the adhesive to form a perimeter seal

Abstract: A method of forming a waveguide or an optical assembly includes molding a waveguide material, optionally in alignment with one or more optical components. The one or more optical components are aligned in a precision mold that is also used to form the waveguide. A cladding and encapsulation material can also be molded. The molded materials can be used to hold the components together in alignment in a single assembly. A connector structure can be molded as part of the assembly or can be prefabricated and incorporated into the molded assembly to facilitate connecting the assembly to other components without requiring active alignment or polishing of optical fiber ends.

Abstract: The present invention is applicable to the field of sport and leisure accessories and particularly relates to a process for making integral elastic supports as well as to integral elastic supports obtainable by such process. The invention also relates to a mold for making such supports, as well as a molding apparatus including such mold, for carrying out the above process. The process comprises the step of forming at least one pad element (2) from a resilient material, associated to a frame (3) made of a substantially rigid or semirigid material whose outer edge (8) defines a peripheral portion (9), in combination with said pad (2). The process is characterized in that it comprises a step of forming a bead (10) from a substantially waterproof material near said peripheral portion (9), to prevent any undesired infiltration in such portion.

Abstract: In order to provide a tubular moulding with a wall, which has high compressive strength and high mechanical stability with good temperature resistance and good chemical resistance, it is proposed that the wall comprises a composite, which comprises a plastics material layer, which is formed from a material containing a fluoropolymer material, and a reinforcement layer.

Abstract: A connector and tubing assembly including a multi-lumen molded connector having at least three flexible tubes also molded into the connector. The connector may be “Y” shaped and include three flexible tubes. A process of making the connector and tubing assembly involves forming a first part of the connector with two tubes molded therein and then removing an internal mold member prior to molding the final connector portion and third tube in place.

Abstract: A method of forming a multi-component molded article is described. The method includes first introducing a first plastic film and a second plastic film separately into a first cavity of an injection mold, the first and said second plastic films each being positioned within the first cavity so as to form a void there-between. Next, a first thermoplastic material is injected into the void, thereby forming a first molding. The first molding is then released from the mold, and the first molding and at least one second molding are together introduced into a second cavity of the mold. Finally, a second thermoplastic material is injected into the second cavity of the mold, thereby combining the first molding and second molding together thus forming a multi-component molded article.

Abstract: A method of joining a first structure to a second structure using a joint element. The joint element has a base and at least two legs extending from the base and the legs define a slot having opposing sides and a bottom. The method comprises attaching the joint element to the first structure and inserting the second structure into the slot. The method further includes injecting an adhesive into the slot. The method also includes ensuring a cavity is formed between the bottom of the slot and the second structure and the cavity is substantially free of adhesive.

Abstract: A fiber forming bushing assembly includes a frame and a bushing within the frame. One or more sections formed of a pre-cast refractory material are positioned between at least a lower sidewall of the bushing and the frame.

Abstract: A method of surface treating a thin titanium foil having a thickness of less than about 3 mils is used to facilitate adequate bonding of the foil with an adhesive. The method includes cleaning the foil with an acid solution and further cleaning the foil using an ultrasonic water treatment. Additional steps that may optionally be performed in between the acid solution and the ultrasonic water treatment include cleaning the foil with a first alkaline cleaner, followed by etching and desmuting the foil.

Abstract: A thermal interface material includes a macromolecular material having two opposite Surfaces, and a plurality of carbon nanotubes each having two opposite ends embedded in the macromolecular material. The two opposite ends of the carbon nanotubes extend out of the two opposite surfaces of the macromolecular material respectively. A method for manufacturing the thermal interface material is also provided.

Abstract: A method of joining a first structure to a second structure using a joint element. The joint element has a base and at least two legs extending from the base and the legs define a slot having opposing sides and a bottom. The method comprises attaching the joint element to the first structure and inserting the second structure into the slot. The method further includes injecting an adhesive into the slot. The method also includes ensuring a cavity is formed between the bottom of the slot and the second structure and the cavity is substantially free of adhesive.

Abstract: A ceramic structure includes a plurality of porous ceramic members each being warped, each of the plurality of porous ceramic members having a bonding portion and end portions at both ends of each of the plurality of porous ceramic members in a longitudinal direction of each of the plurality of porous ceramic members, and an adhesive provided only on the bonding portion between the plurality of porous ceramic members to connect the plurality of porous ceramic members except for the end portions of the plurality of ceramic members.

Abstract: Molding equipment and related techniques for forming a golf ball are disclosed. The molding equipment includes the use of a mandrel with a spherical portion sized to fit within a molding chamber. The molding equipment and related processes are particularly useful when forming the various layers by reaction injection molding.

Abstract: A method of manufacturing a seal in an electrosurgical device includes placing components of the electrosurgical device within an elongated housing section, the housing section including an actuator opening, introducing the housing section within a mold filled with a liquid thermoplastic elastomer and allowing the elastomer to flow within the housing, forming an elastomeric inwardly-extending lip portion circumferentially surrounding an opening at a distal end of the electrosurgical device for introducing an electrode therein, and allowing the molded elastomer to cure and become integral with the housing to seal the components within the molded elastomer contained within the housing section. The method may also include the step of forming an elastomeric actuator seal around the actuator opening.

Abstract: The invention relates to a method of manufacturing a catheter, wherein the catheter comprises an elongate portion having a proximal end and at least one lumen at said proximal end, at least one extension tube having a passage, and a coupling element, the distal portion of the extension tube being capable of communicating with a lumen of the elongate portion via a passage in the coupling element wherein the method comprises a step wherein a removable insert element locates and holds the extension tube in contact with the elongate portion during the manufacture of a coupling element. The invention also relates to a removable insert for use in the manufacturing of catheters.

Abstract: A boat hull or an aircraft or spacecraft fuselage is constructed by laying up perforated architectural wood veneer strips which have been designed to create the desired shape and overlap one another. A layer of strips is placed in or on a mold of the final desired shape, with each piece slightly overlapping the previous piece. The strips are bonded to one another using epoxy resin or other adhesives. The thickness of the wood strip at the overlap creates a chaseway of air along the length and ends of the each piece of adjoining wood veneer. The chaseways, in conjunction with perforations made in the wood veneer, permit the infusion of resin and removal of air without requiring any additional medium or device. The gap-filling capability of the epoxy and the thinness of the veneer give the final panel a smooth surface in spite of the veneer overlaps.

Abstract: A method of manufacturing a composite sheet includes perforating a reinforcement panel. A mold surface onto which the composite sheet may be formed is provided. At least one outer coat of material is applied onto the mold surface. At least one coat of resin and reinforcement material is applied over the outer coat to form a reinforcement layer. The perforated reinforcement panel is applied to the reinforcement layer, and the resin is forced into the perforations formed in the reinforcement panel, thereby bonding the reinforcement layer to the reinforcement panel.

Abstract: The invention is a process for the preparation of article comprising placing a film on each inner surface of each part of a two part mold; placing an article in the mold with film located between the surface of the mold and the article such that there is a small space between the article and the surface of the mold; closing the mold about the article; injecting between the film and the article an expandable plastic material under conditions that the article is coated with the expandable material and the expandable material does not expand; removing the plastic article with the expandable material coated thereon with the two films attached to the expandable plastic material. In another embodiment the invention is an article comprising a shaped plastic article; an expandable material coated in the shaped plastic article; and a film covering the material coated shaped plastic article.

Abstract: A molding die 1 is constituted by an upper die 1a and a lower die 1b which are made of a material transparent to an ultraviolet light, and has a cavity 3 constituted by grooves 2c, 2d, whereas a resin injection gate 4 and a resin exit gate 7 are provided so as to communicate with the cavity 3. A junction of an optical fiber 10 is inserted into the cavity 3. A UV-curable resin is injected into the cavity 3 surrounding an exposing portion of the glass optical fiber 11 from the resin injection gate 4 positioned at one of coating ends of the optical fiber 10, whereas a part thereof is discharged from the resin exit gate 7 positioned at the other coating end. The ultraviolet light is emitted through the lower die 1b so as to cure the resin, thereby forming a reinforcement resin coating. As a consequence, bubbles can be prevented from occurring due to the residual air within the reinforcement resin coating in the junction of the optical fiber 10.

Abstract: Liquid laminating resin systems are used to attribute hurricane resistant properties to insulated glass window units. The activated resin system is then deposited on a single piece of float glass with the containment insulating unit or the resin can be injected between the air space of an existing insulated unit. In the first case, the second piece of glass completes the insulating unit. In both cases, the resin is allowed to cure 3–4 hours. The finished insulated and impact-resistant glass unit can then be installed into the window frame structure. Preferred resins include multiple component polyurethanes and special low shrinkage polyester systems with Argon gas between the glass layers after the resin has cured.

Abstract: A method of manufacturing a composite fluted sheeting material comprising at least two surfaces interspersed with a plurality of substantially parallel spaced webs forming a plurality of elongate semi closed cells (5), and a filler material set within said cells; the method including the steps of: (f) applying a blank fluted sheet to a receiving station (7); (g) preparing a filler material for delivery to a filling station; (h) moving said blank sheet and/or said filling station relative to each other such that said filling station moves in a linear direction transversely across the open ends of said elongate semi closed cells of said sheet; (i) dispensing said filler material to said cells; allowing said filler material to set.

Abstract: The invention relates to a method of fabricating a bipolar plate for fuel cell stacks, wherein the bipolar plate includes a circumferential frame made of an electrically non-conductive material and further includes an inner bipolar plate region which is enclosed by the frame, is made of the electrically non-conductive material and comprises channels for gases and, if required, for coolants, said method comprising the following procedural steps: A) Inserting an electrically conductive fabric into a tool for fabricating the bipolar plate, B) Introducing the electrically non-conductive material into the tool in order to form the frame and the inner bipolar plate region (3), the electrically non-conductive material extending through the fabric, C) Removing a molded bipolar plate from the tool, and D) Bending back the fabric on both sides which extends beyond the inner bipolar plate region so as to cause the fabric to cover the inner bipolar plate region made of the non-conductive material.

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