Abstract: A method for building a three-dimensional object, the method includes positioning a metal part within a build chamber of an extrusion-based layered deposition system, where the metal part comprising a polymer-coated surface. The method also includes depositing a build material on the polymer-coated surface of the metal part, wherein the deposited build material cools to form at least a portion of a layer of the three-dimensional object.

Abstract: Lightweight, thermoplastic, vehicle headliners each having at least one integrally-formed, energy-absorbing, head-impact mechanism and injection molding methods for making same are provided. Each headliner includes a stiff, self-supporting, thermoplastic sheet adapted to be mounted adjacent a roof of the vehicle so as to underlie the roof and shield the roof from view. The sheet has an upper surface and a lower surface. Each energy-absorbing, head-impact mechanism absorbs energy of an impact with its associated headliner by a passenger of the vehicle. In one embodiment, the at least one head-impact mechanism includes a plurality of spaced-apart, energy-absorbing, thermoplastic structures, such as ribs, which are connected to and extend upwardly from the upper surface of its thermoplastic sheet.

Abstract: A method for using a single injection molding apparatus to manufacture at least two and up to four different levels of automobile trim pieces as well as automobile trim level pieces manufactured by the methods of this invention.

Abstract: Methods for molding a surround over a liner to form a composite shell are provided. The liner is placed in a mold and molten surround material is injected into the mold so as to surround the liner. A surface of a protrusion of the liner abuts the mold so that the surface is exposed and is substantially flush with an exterior surface of the surround after the composite shell is removed from the mold. Molten surround material flows into a slot in a perimeter of the protrusion so that when the surround material solidifies, a rib of surround material extends into the slot to form a pressure seal between the liner and the surround. An adhesive is applied to the liner before placing the liner in the mold for reducing relative movement between the liner and surround as the surround material solidifies and the liner and surround cool.

Abstract: A high-performance plain bearing provided with a friction coating including a bronze layer whereof the pores are filled with a PTFE-type fluoroplastic paste filled with molybdenum bisulphide. The production method includes sintering a layer of bronze powder on the metal support of the bearing, a vacuum ionic cleaning, applying a filled fluoroplastic film, passing the component through a die and after sintering the paste, a final pass in the die for final dimensioning. During sintering and passing through the die an anti-adhesive and wear-resistant coating, based on titanium nitride or the like, is applied on the equipment.

Abstract: The invention relates to a layered structure comprising a plastic substrate, at least one intermediate metallic layer on top of this plastic substrate and a metal or metal alloy layer on top of this intermediate metallic layer. The metal or metal alloy layer is applied from the melt of a metal or metal alloy. The invention further relates to a method of manufacturing such a layered structure.

Abstract: In the production of a vulcanized rubber-resin composite material by providing a vulcanized rubber molding in a mold, followed by injecting a resin into the mold, a vulcanizable adhesive layer containing brominated poly(2,3-dichlorobutadiene-1,3) as the main component is formed on the surface to be bonded of the vulcanized rubber molding, and then injecting the resin while keeping the vulcanizable adhesive layer to stay as formed on the surface to be bonded, thereby effecting the bonding, where a strong adhesion is established between the vulcanized rubber molding and the resin layer without any heat treatment of the vulcanized rubber molding before provision of the vulcanized rubber molding in the mold or without any heat treatment of the composite material after the resin injection.

Abstract: The present invention involves a process that includes injecting a potting compound such as an epoxy through a hollow portion (2B) of the central mandrel (2) and onto the inner layer(s) of a multi-layered fiber bundle (3) and through the outside of the bundle and onto the outer layer(s) of the bundle. By potting through the central mandrel (2), the potting compound distributes evenly throughout the inner fibers of the bundle (3). The steps may be sequentially or simultaneously. Preferably it is done as a two-step process, with the first step being to apply the potting compound through the central mandrel (2) and onto the inner fibers first. The second step is to pot around the outer layer of the fiber bundle (3) to finish the process. The resultant product is also disclosed.

Abstract: A method of providing a molding article with a plush surface is provided. The method includes providing a flocked transfer, securing the transfer in place in a mold, and molding the article such that the transfer is embedded in the surface of the article. The article can be injection molded.

Abstract: A process of molding a component on a substrate utilizes a substrate having a peripheral flange that projects into a parting line between mold segments defining a mold cavity, wherein the flange has a projecting, continuous circuitous ridge that forms a seal between the substrate and an upper mold segment. The process allows a substantially flash free molded component to be formed directly on a substrate, thus eliminating the need for a separate flash removal step.

Abstract: A pull through such as might be used for an endoscope where a thermaplastics monofilament substantially free of spool or coil memory has molded thereon a desirable thermoplastic mass profile in a material of lower melting point than at least part of the filament, such melting point differential with preferably pre-heating of the filament ensuring an appropriate keying of the profile on the filament.

Abstract: In a method for producing a brake shoe (1), particularly a brake shoe for disk brakes in motor vehicles, by preforming a friction lining (6), arranged on a carrier plate (2), from a friction material fed into a press mould and by press-molding the friction material under pressure and heat to form a friction lining (6), it is provided that grooves (8) are formed in the friction lining (6) which are open at least towards the front face of the friction lining, that the friction lining (6) provided with grooves (8) is exposed to a scorching process, that, subsequent to the scorching process, an elastic filling agent (12) is inserted into the grooves (8), and that, subsequent to the insertion of the filling agent (12), the brake shoe (1) is subjected to a drying process, a hardening process or a cross-linking process depending on the filling agent (12) used.

Abstract: A coating position at which an water sealing agent in an unsolidified condition is coated on an outer periphery of each wire is provided. A first mold formed with a groove and a second mold configured to be inserted into the groove are provided. The second mold has a molding face which defines a space between a bottom portion of the groove. The space has a cross section which is identical with a cross sectional shape of a through hole of a grommet through which the wires are inserted. The wires are conveyed one by one so as to pass through the coating position while coating the outer periphery of each wire with the water sealing agent. The wires coated with the water sealing agent are thrown into the groove of the first mold. The second mold is inserted into the groove to press the wires in the groove such that the unsolidified water sealing agent fills interstices of adjacent wires while solidifying the water sealing agent.

Abstract: A method for producing a plastic part having a first component and a second component connected to the first component. The method includes molding a temporary connection between the first component and a preliminary second component, coating at least a surface region of the first component, separating the first and preliminary second component, and then molding the second component to the first component. The plastic part can be an injection molded part and the components of the plastic part can be made using the same or different plastics.

Abstract: The present invention is a process for producing an injection-molded thermoplastic work piece having a thermoset coating bonded thereto, comprising the steps of introducing into a closed mold a thermoplastic material, such as a polyolefin, heated to a temperature above its melting point and molding said material to form a work piece; followed by introducing a thermoset coating composition capable of generating free radicals into the closed mold to contact at least a portion of a surface of the work piece, the temperature of which is at or above the temperature at which free radicals contained in the coating composition are generated. The mold is then opened and the work piece is removed after the coating composition has at least partially cured. The present invention is also directed to a molded article made by the described process.

Abstract: A sensor is provided for the determination of various concentrations of one or more components within a fluid sample. The sensor includes an injection molded body, at least two electrodes, an enzyme, and if desired, an electron transfer mediator. The body includes a reaction zone for receiving a fluid sample. The electrodes are at least partially embedded within the plastic body and extend into the reaction zone. Also contained within the reaction zone is an enzyme capable of catalyzing a reaction involving a compound within the fluid sample. Additionally, the sensor incorporates fill detection which activates a meter, attached to the sensor, for measuring the electrochemical changes occurring in the reaction zone.

Abstract: A method for using a single injection molding apparatus to manufacture at least two and up to four different levels of automobile trim pieces as well as automobile trim level pieces manufactured by the methods of this invention.

Abstract: A method is disclosed for pre-conditioning inserts for improved replication during injection molding. The pre-conditioned inserts provide improved bonding with the injection-material and improved replication of complex molding surfaces. The pre-conditioning of the inserts comprises placing the insert in position against the molding surface, followed by heat-soaking the insert. Heat-soaking can be accomplished using infrared energy, preferably broadband infrared energy or energy that is preferentially absorbed by the insert.

Abstract: The present invention is a grooved belt, or surface roll where applicable, and a method for making these belts or rolls, comprising placing a chemically reactive material on a partially completed belt surface, and depositing an elastomeric material onto the chemically reactive material which reacts and forms a bond therewith to create a pattern. Placement of the elastomeric material is used to create the grooves, for example. The grooves are formed without machining and the resulting belt surface is smooth and uniform without cuts or cracks.

Abstract: A forming method of a rubber layer covering the metallic handle of a pneumatic tool includes the following steps: providing a support rod in the opposite openings of the hollow metallic handle of a pneumatic tool, coating rubber metallic bonding agent on the outer surface of the handle, placing the handle coated with bonding agent into a mold, injecting melted rubber into the mold to be molded in shape and finally opening the mold and taking out the handle with a rubber layer thereon.

Abstract: A method for manufacturing tiles for use in a raised floor system is disclosed. The tiles comprise an outer shell and an inner core material. The method includes constructing the shells at a manufacturing facility, transporting the shells to a remote location associated with a job site, and filling the shells with a fill material at the remote location. A method is also disclosed for providing a rack to hold the tiles during the manufacturing process, stacking shells in a vertical orientation on the rack, and filling the shells with a core material while on the rack.

Abstract: A method of manufacturing a semiconductor mounting board includes providing a base member and linear conductive members formed of metallic wires. The conductive members are constructed so that they extend linearly between a semiconductor element-mounting face and a circuit board-mounting face of a base member, and are integrally molded within the base member. For this purpose, a resin material for forming the base member is injected into a mold wherein the conductive members are linearly arranged beforehand.

Abstract: An injection molding method for a polyamide resin molded article in which an already-molded article including a polyamide resin is set in a molding die and, then, the polyamide resin, which has been heated so as to be in a molten state, is injection-filled in a cavity to which a part of the already-molded article faces thereby integrally molding an additional molding part onto the part of the already-molded article. A primer is applied to a predetermined integral molding part, and then the thus primer-applied already-molded article is set in the molding die. The primer includes an alcohol solution containing the polyamide resin and a chemical that is capable of dissolving the polyamide resin.

Abstract: A method of forming a reinforced urethane product having a urethane wear layer and a integral reinforcing member. A reinforcing member is formed from a woven fiber material that has a shape generally corresponding to the desired urethane product, such as a composite urethane pipe. The reinforcing member is initially stiffened through application of a sizing compound. Once stiffened, the reinforcing member is inserted into a mold and a supply of urethane is forced outward toward the inner wall of the mold cavity such that the urethane penetrates into the woven fibers of the reinforcing member. The urethane is cured in the mold and the completed reinforced urethane product is removed from the mold for use. The liquid urethane is preferably forced outward within the mold through application of either a centrifugal force or the application of positive pressure.

Abstract: A method of providing a protective barrier between a plastic casing and a rubber layer molded over the plastic casing. The protective barrier is applied to the plastic casing and then the rubber layer molded onto the plastic casing over the protective barrier. The protective barrier prevents the rubber layer from reacting with the underlying plastic casing. In one embodiment, the plastic casing comprises a polycarbonate resin and the protective barrier comprises a polyurethane coating.

Abstract: An illuminated cover and a method of making such a cover. An electroluminescent foil overlies a thin, rigid support base, and an insulating foil overlies the electroluminescent foil. A first opening allows insertion of an electrical connector for the electroluminescent foil. A second opening allows insertion of a control key of a device covered by the decorative cover. The covered electronic device further includes a printed circuit board having electronic components mounted on it, including the control key. A connector extends into the first opening to connect the electroluminescent foil to circuitry on the printed circuit board so as to provide electrical power to the electroluminescent foil. A graphic can be included between the electroluminescent foil and the insulating foil. The cover is made by a molding method.

Abstract: An injection molded component having at least one structural layer of material and at least one fuel vapor barrier layer carried by the structural layer, and a method of making it utilizing separately injection molded structural and fuel vapor barrier layers. The vapor barrier layer may be trapped between two other interconnected layers, or may be bonded to a structural layer by an adhesive. In one form, a fuel vapor barrier layer and a structural layer are separately molded onto a preformed adhesive layer. Desirably, the heat generated during the steps of molding both the vapor barrier layer and the structural layer onto the adhesive layer is sufficient to activate the adhesive and bond the layers together. In another form, a fuel vapor barrier layer is bonded to a layer comprised of a blend of structural and adhesive materials. In yet another form, a fuel vapor barrier layer is disposed and captured between two interconnected structural layers.

Abstract: Decorative transfers that can be directly applied to a mold surface during the molding process are created. The decorative transfers include an uppermost intermediate layer that includes a tacky resin. The decorative transfers also include inks that specify a desired image. Tacky inks and/or tack-free inks are used in the decorative transfers. Preferred decorative transfers include crosslinkable polymers in all of the intermediate layers.

Abstract: Methods for molding a surround over a liner to form a composite shell are provided. The liner is placed in a mold and molten surround material is injected into the mold so as to surround the liner. A surface of a protrusion of the liner abuts the mold so that the surface is exposed and is substantially flush with an exterior surface of the surround after the composite shell is removed from the mold. Molten surround material flows into a slot in a perimeter of the protrusion so that when the surround material solidifies, a rib of surround material extends into the slot to form a pressure seal between the liner and the surround. An adhesive is applied to the liner before placing the liner in the mold for reducing relative movement between the liner and surround as the surround material solidifies and the liner and surround cool.

Abstract: Shaped load-carrying structures are fabricated using bamboo linear fibers with a compatible bonding material and synthetic polymers such as polyesters, epoxies, and polyolefins. The structures are manufactured by coating at least one of bamboo culms, split bamboo culms, bamboo fiber tape, or prepared bamboo fibers with a bonding material to produce a core. The core is then combined with a polymer matrix and extruded or molded to form a structure having the desired shape. The structures compare favorably with wood, steel, and concrete regarding strength, longevity, price and ability to withstand earthquakes. The structures may be used as beams, columns, telephone poles, marine piles and pallets.

Abstract: A process is disclosed to eliminate or diminish oxygen inhibition of the curing of coating resins in the composite industry. A free radical curable coating is applied to a mold surface and an inert gas is used to protect the coatings from oxygen in the air during the cure. The inert gases can be, but are not limited to, nitrogen gas and carbon dioxide gas. The inert gas or mold or both can be heated to a temperature above room temperature.

Abstract: The present invention relates to a method and installation for integrally applying a relief decoration to the surface of solid elongate members. The installation comprises a pre-heater (43) with pre-heater control means (69), a press (51), and a camber measurement system (67). The pre-heater (43) is adapted for differently heating the surface of two opposing faces of an elongate member previous to feeding it to the press (51) for applying the relief decoration. The camber measurement system (67) measures possible camber of the elongate member coming out of the press (51) and generates camber measurement signals which are fed back to the pre-heater control means (69) for controlling the heating of the pre-heater (43). The aim of the installation of the present invention is to eliminate the camber of following elongate members to which a relief decoration is to be applied.

Abstract: A preform and container each having a crystallized neck finish and method of making the same, wherein the method involves introducing a first thermoplastic material into a first mold section to form a substantially crystallized neck portion of a preform, and introducing a second thermoplastic material into a second mold section to form a substantially amorphous body-forming portion of a preform. The first material may have a substantially higher crystallization rate than the second material, and/or the first mold section may be at a higher temperature than the second mold section. In one embodiment, an indexer carrying two core sets is movable between first and second cavity sets for sequentially molding the neck portions on the first core set in the first cavity set, and then transferring the cores and neck portions to the second cavity set for molding the body-forming portions.

Abstract: A method of manufacturing a composite molded product is disclosed, so as to improve the adhesion between the insert material and the base resin. The method comprises the steps of coating an insert material with primer; coating surface of the primer with dope cement; and subjecting the insert material coated with the dope cement to insert molding. The adhesion between the insert material and the base resin is superior; thus, substandard products having a portion which breaks away or protrudes are hardly generated. In addition, a surface material in which the insert material is coated with the dope cement has a very small degree of camber; thus, punching or the like for shaping the surface material can be easily performed after the coating.

Abstract: A multi-layer preform, includes: (a) a plastic inner liner, comprised of a cylindrical walled body, which may or may not include a tapered annular shoulder portion, and a cylindrical walled neck portion extending upwardly from the body, and (b) a molded outer layer. Prior to the outer layer being molded over the plastic inner liner, at least a portion of the liner is crystallized by a heat treatment process. The molded outer layer may include a means to receive a closure device. When the preform is at an acceptable temperature range for orientation, the multi-layer preform can be blow-molded to form a multi-layer container having improved properties.

Abstract: A composite plastic structure is described. The composite structure includes: (a) a shaped polycarbonate article having an edge region, the edge region having an adhesion-promoting geometric feature therein; (b) a coating applied to the surface of the shaped polycarbonate article; and (c) a polymer that is injection-molded or cast over the edge region of the shaped polycarbonate article. The polymer (c) envelopes the adhesion-promoting geometric feature of the shaped polycarbonate article (a). The envelopment of the adhesion-promoting geometric feature by the polymer (c) provides a structurally firm connection between the shaped polycarbonate article (a) and the polymer (c). Also described is a method of preparing the composite structure, and composite structures according to the present invention, such as picture frames, slide frames, windows having a seal or frame, and a glazing for a motor vehicle.

Abstract: There are provided (I) a laminate comprising:

Abstract: A method of producing a rubber-resin composite whose vulcanized rubber and thermoplastic resin moldings are bonded together by high adhesive strength at low cost, satisfying both moldability and mechanical strength. It comprises: (1) making the vulcanized rubber molding by vulcanization molding, (2) forming an adhesive layer, whose principal ingredient is chlorosulfonated polyethylene, on a surface of the rubber molding to be bonded to the resin, and (3) while arranging the rubber molding in a mold, pouring the thermoplastic resin containing 30˜60 wt. % of glass fiber in a molten state into the mold to form the resin molding.

Abstract: In a method of molding, a decorative substantially transparent cycloaliphatic polyester resin substrate is formed into a three-dimensional shape, placed into a mold, and a resin is injection molded into the mold cavity space behind the formed substrate.

Abstract: A resin multilayer molding method in which a skin material having a resin decorating layer on a surface and a core-material resin are integrally molded in a mold, comprising the steps of: presetting a relationship of a glass transition point (Tgs) of the resin decorating layer of the skin material and a supply temperature (Tc) of a molten resin forming a core material to satisfy Tgs<Tc, and performing molding on a condition that a maximum temperature (Tsm) of the resin decorating layer of the skin material during clamping satisfies Tsm>Tgs.

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

Abstract: A process for producing a composite article from at least one polar thermoplastic, in particular an engineering thermoplastic, and from at least one foamed or unfoamed polyurethane elastomer, where a molding is firstly molded from the thermoplastic, and some or all of this is provided with an adhesion promoter based on acrylic-resin lacquer or polyurethane-resin lacquer comprising solvents, and then a coating which may be in full-surface or strip form or at least one other molding made from the polyurethane elastomer is used for overmolding, and the thermoplastic material is thus bonded to the polyurethane material.

Abstract: A flat composite body with an asymmetric laminar structure generally consisting of a first layer of material, a foam core intermediate layer and a decorative second layer of non-metallic material, wherein a fleece with an epoxy binder is placed between the first and intermediate layers and a fiber matting with an epoxy binder is placed between the intermediate layer and the second layer.

Abstract: A three-dimensional, multi-layer plastic product that is resistant to damage caused by environmental factors such as heat, chemicals, desiccants, oxygen, and/or weather is disclosed. The multi-layer product includes an engineering resin layer affixed to a commodity resin layer. The engineering resin layer of the multi-layer film may be directly fused to the commodity resin or post-consumer regrind layer. Alternatively, the engineering resin layer may be tied to the commodity resin or post-consumer regrind layer through the use of one or more adhesive and/or tie layers. The commodity resin layer may be manufactured from an economical polymer material such as a polypropylene, polyethylene, polystyrene or post-consumer regrind.

Abstract: The present invention involves a process that includes injecting a potting compound such as an epoxy through a hollow portion (2B) of the central mandrel (2) and onto the inner layer(s) of a multi-layered fiber bundle (3) and through the outside of the bundle and onto the outer layer(s) of the bundle. By potting through the central mandrel (2), the potting compound distributes evenly throughout the inner fibers of the bundle (3). The steps may be sequentially or simultaneously. Preferably it is done as a two-step process, with the first step being to apply the potting compound through the central mandrel (2) and onto the inner fibers first. The second step is to pot around the outer layer of the fiber bundle (3) to finish the process. The resultant product is also disclosed.

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

Abstract: A pull through such as might be used for an endoscope where a thermoplastics monofilament substantially free of spool or coil memory has moulded thereon a desirable thermoplastic mass profile in a material of lower melting point than at least part of the filament, such melting point differential with preferably pre-heating of the filament ensuring an appropriate keying of the profile on the filament.

Abstract: A process for forming an injection molded article including multiple appliques. The process generally includes the steps of: positioning in a mold a first applique including a edge; positioning in the mold a second applique including a terminating end; abutting the second terminating end against the edge in a non-overlapping, substantially perpendicular configuration; injection molding a thermoplastic resin around the appliques to form an article. Because the first and second appliques do not overlap, they will not separate from one another over the life of the injection molded article. Accordingly, multiple applique articles formed according to the process of the present invention maintain their structural integrity and are resistant to warping, peeling and/or separation of the appliques from one another.

Abstract: A female mold for plastic sanitaryware manufacture has an open top to promote improved air escape from the mold as resinous backing resin fills the mold in order to reduce the number of gas inclusions within the backing material after it is cured. The female mold also provides thermal insulation for the curing backing material to permit better curing and to reduce the potential for delamination in the finished product. A production fixture is equipped with a gas impermeable lid for selective contact with the female mold, after the air has been expelled from the mold, in order to control undesirable styrene emissions.

Abstract: A continuous paste making process for lead acid batteries that includes the steps of mixing water with a lead oxide, reaction an acid with the lead oxide in a mixture to produce lead acid compounds, and forming a paste including interlocking lead acid crystals from the lead acid compounds, where the mixing, reacting, and crystal forming steps occur in an extrusion apparatus. The method also includes the step of extruding the paste from the extrusion apparatus into a grid where the paste is dried to form a battery plate of the lead-acid battery.