Abstract: A method and means for attaching flexible, low density or compressible structure such as foam to injection molded parts, wherein a mold has a recess shaped for a corresponding flexible, low density or compressible structure. A valve plate made of injected material is placed against the foam structure to compress and protect the foam structure from molten injected material. The valve plate has through apertures for limited access of the injected material to predetermined surface portions of the foam. The molten injected material forms an adhesive between the foam structure and valve plate to adhere the foam structure to the valve plate, and the resultant final component assembly.

Abstract: A method of producing a structural component (12) from a primary wall structure (14) which defines a plurality of juxtaposed primary cells (15) which extend between and which are open to the front face and the rear face of the component (12) and a secondary wall structure (16) within the primary wall structure (14) which divides each primary cell (15) into two or more subcells (151, 152) comprises first forming the primary wall structure (14) and then forming the secondary wall structure (16) within the primary wall structure (14) by bringing the primary wall structure (14) into a condition in which it lies within a body of liquid the surface of which provides or is provided with a photosensitive layer and in which the photosensitive layer is at a predetermined level in each primary cell (15) and exposing the photosensitive layer to a radiation source to bring the photosensitive layer to a consolidated state within the primary wall structure (14) to form the secondary wall structure (16).

Abstract: A composite insulator-producing process including the steps of forming the housing from the housing-forming insulating polymer material and then vulcanized around the outer periphery of the rod-shaped core member by using the mold in the state that the core member is mechanically or thermally expanded by substantially (.delta.-.alpha.) or more in which .delta. is an axially linear expanded length by which the core member would be thermally expanded if the core member is heated to a molding temperature for the housing, and .alpha. is an axially linear expanded length by which the mold would be thermally expanded if the mold is heated to a molding temperature.

Abstract: In the assembly of a windshield glass and a weather strip having a partly modified cross section the weather strip is extruded along the peripheral edge of the windshield glass and fixedly adhered thereto, a movable die 132 of a die assembly is properly moved so as to change the shape of an orifice of the die assembly.

Abstract: A seal for movable structural components, like piston rods or shafts, includes a carrier body made of thermoplastic material and a sealing member locked to said carrier body and made of polytetrafluoroethylene (PTFE) material. A form-lock connection is achieved by an undercut which is formed permanently in the sealing member and filled with plastic material of the carrier body.

Abstract: The present invention is an element for gripping metal to be stretched by a stretcher leveler apparatus. The gripping element includes a first and preferably a second high density cast polyurethane gripping pad adapted for engagement with the metal to be stretched and a support member which can be a rectangular plate upon which the first and second gripping pads are operatively anchored. The support member having two pads is detachably mounted to the stretcher leveler apparatus either in a first orientation in which the first pad is positioned for engagement with the metal to be stretched or a second orientation in which the second pad is positioned for engagement with the metal to be stretched. Preferably, the support member is a plate having a first support surface upon which the first gripping pad is chemically bonded and a second support surface upon which the second gripping pad is chemically bonded. The support surfaces are disposed on opposite sides of the plate and in a parallel relationship.

Abstract: A golf ball has a core (1) enclosed with a cover (2) wherein the cover (2) is embossed on its surface with dimples by compression molding in a mold and includes an innermost layer (3), an intermediate layer (4), and an outermost layer (5). The intermediate layer (4) and the outermost layer (5) are formed of a laminate film while the outermost layer (5) is made of a material which is smoothly releasable from the mold. The golf ball is readily removed from the mold at the end of molding and has a high precision of dimple geometry.

Abstract: A branched hose construction, hose unit therefor and methods of making the same are provided, the branched hose construction comprising a first tubular hose unit having opposite ends and having a tubular branch extending outwardly therefrom intermediate the opposite ends and having a free end, a second tubular hose unit having a free end telescoped with the free end of the tubular branch, and fastening structure interconnecting the telescoped free ends together, the fastening structure comprising a quick connect/disconnect structure, the second tubular hose unit comprising an end of a flexible hose and part of the quick connect/disconnect structure molded onto the flared end of the flexible hose and extending outwardly therefrom.

Abstract: An apparatus for producing patterned molded articles includes an injection mold composed of a first mold and a second mold, an unwind roll for unwinding a continuity of pattern film, a film introducing device for introducing the pattern film unwound from the unwind roll to between the first mold and the second mold, and a main clamp for pressing the pattern film against a surface of the first mold. A cutting device is provided on the upstream side of the surface of the first mold and serving for cutting off the pattern film, and a sub-clamp provided on the downstream side of the surface of the first mold and serving for fixing a cut-off end portion of the pattern film. The film introducing device has a pinch device for grasping the cut-off end portion of the pattern film and a driving device for reciprocatingly moving the pinch device.

Abstract: The method for making a graphic representation on objects made of a polyolefin polymer, consists of printing a graphic representation on a face of a first film made of a stretched polymer, chosen among a polyester polymer and an acrylic polymer, associating the first film with a second film in order to obtain a membrane formed by the associated first and second films containing the graphic representation between them, transferring the membrane inside an injection mold and injecting a polyolefin polymer in the mold for forming the object, obtaining at least a partial melting of the second film so that the membrane forms one body with said object.

Abstract: A method of making an encapsulated transducer (10), which includes an injection molded encapsulation (20) having a front end (22) and a back end (24). The encapsulation (20) is a monolith of cured moldable material ensconcing a sensing element (90) proximate the front end (22) and a portion of an information transmitting medium (120) emanating from the back end (24). A component alignment preform (40) operatively couples the sensing element (90) with the information transmitting medium or cable (120). The component alignment preform (40) includes a front ferrule (70) and a rear ferrule (80) bonded thereto and linearly spaced apart along a long axis "A". The component alignment preform (40) further includes an annular recess (44) in which the sensing element or coil (90) is placed so that it is linearly spaced and aligned along the common long axis "A" in which the front and rear ferrules (70), (80) are aligned.

Abstract: A heating device used for a simultaneous injection molding and patterning method such that: a decorative pattern sheet is disposed between a pair of mutually opposed molds (mold A formed with a vent and mold B formed with an injection gate); the decorative pattern sheet is heated and softened by the heating device; the decorative pattern sheet is brought into tight contact with a cavity surface of mold A on the basis of a pressure difference caused by exhaustion of mold A through the vent; and a molten resin is injected into the molds through the injection gate to mold a product patterned on the basis of the decorative pattern sheet.

Abstract: A method of bonding various materials, such as foam materials, to thermoplastic resins using a silane composition is provided. The thermoplastic resin is doped with a silane by washing the thermoplastic resin in a silane solution and then evaporating the solution from the resin. The silane-doped thermoplastic resin is then melted and formed into a polymeric article. In one embodiment, a polyurethane foam can then be sprayed onto the polymeric article. As the foam forms on the surface of the article, it bonds with silane trapped within the thermoplastic resin. In one embodiment, the polymeric article can be formed through a rotational molding technique. Through the process of the present invention, many useful articles can be formed such as polymeric pallets, water craft devices, thermocoolers and the like.

Abstract: An apparatus and method forms multiple resin layered parisons that are cooled or blown into bottles. The individual resin layers are injection molded in sequence and the formed parisons are transferred to each cooling and molding station by an axially and laterally indexing platen.

Abstract: A method for producing a multilayer molded article that includes a resin body and a skin material on a surface of the resin body, which method uses a mold having male and female molds. The shortest horizontal distance of a mating gap between the horizontally outermost wall surface of the male mold to which the skin material contacts and the horizontally innermost wall surface of the female mold to which the skin material contacts is 0.25 to 3 times the minimum thickness from which the once compressed skin material can restore the original thickness. The shortest length L in a mold closing direction of a mated part formed between the outermost wall of the male mold to which the resin melt contacts and the innermost wall of of a flange of the female mold satisfies the equation:(t.sub.1 -t.sub.0 +10)mm.gtoreq.L.gtoreq.(t.sub.0 -t.sub.0)mmwherein t.sub.1 is a distance (mm) between the male and female molds when the resin melt first reaches the horizontally outermost edge of the male mold, and t.sub.

Abstract: A multi-chip-module comprising a plurality of vertically layered substrates and including a plurality of coaxial inter-connects formed between and through the substrate layers. Each of the coaxial inter-connects is formed by a process wherein: an outer hole (aperture) is drilled through the substrate and lined with an electrically conductive material to form an outer via; the outer via is filled with a dielectric material; and, an inner hole (aperture) is drilled through the dielectric material and filled with an electrically conductive material to form a center via. The characteristic impedance of the coaxial inter-connect is determined by the selection of the outer diameters of the drilled holes for the outer and center vias.

Abstract: Like-new golf balls are made from used golf balls by first reducing the diameter of the used ball, to provide an intermediate ball, and then molding a new dimpled cover on the ball. The diameter of the used ball is uniformly reduced by compression molding or by grinding.

Abstract: Method and apparatus including a powder box and heatable shell tool are disclosed for forming a thermoplastic automotive air bag cover skin with a lesser strength thermoplastic tear seam strip insert wherein the latter is initially formed with a protruding rib on one side and a pointed ridge on an opposite side. A heat resistant elastomeric transfer socket attached to the powder box interior receives and holds the insert rib and thereby the insert in a prescribed tear seam configuration and then positions the tear seam strip insert against a heated skin defining mold surface on the shell tool when the powder box is joined with the latter. The skin is formed by casting thermoplastic powder from the powder box against the heated mold surface and about the tear seam insert.

Abstract: A machine for overmolding an equipment of an underwater cable includes a heated mold. The mold has a fixed half-mold with two side injection molding inlets and a mobile half-mold on a machine frame. These are coupled to a high-pressure injection molding press through an overmolding material distribution chamber and to the ends of the mold cavity. The machine finds an application in overmolding joint boxes and repeater housings.

Abstract: An apparatus for producing a fissured, acoustical ceiling panel wherein the pins used to fissure the panel are roll applied thereto. The pins are embedded in flexible, resilient polymeric plates, and a plurality of the plates are attached to a rotary drum which is used to apply the fissuring pins to the surface of the panel. The invention also includes the method for manufacturing the polymeric plates which are molded and formed with the fissuring pins embedded therein.

Abstract: This invention provides the method of centrifugal casting consisting of the steps of: adding a polymeric material to a centrifugal apparatus; centrifuging said polymeric material until said polymeric material is cast; removing said cast polymeric material from said centrifugal apparatus; and mounting said cast polymeric material to an outside surface of a support, whereby the air interface side of said cast polymeric material is furthest from the outside surface of the support.

Abstract: A method of manufacturing a casing for electronic apparatus use in which metal and resin are subjected to a hybrid formation, so that the mechanical strength of the casing is improved and the thickness is reduced so as to reduce the weight. An electronic apparatus casing having a rib (16) and boss (18) is manufactured when metal (10) and resin (12) are integrally formed. Adhesive (14) is coated on the metal, and after the coated adhesive has been dried, the resin (12) is injected onto the adhesive layer from a portion which composes the rib or boss, so that the metal and resin are subjected to a hybrid formation.

Abstract: A method for fabricating an individually adapted in-the-ear hearing aid shell with a battery compartment cast into the shell such that the door of the battery compartment is flush or slightly recessed in the portion of the shell that contacts the user's ear cavity.

Abstract: A graphic representation is made on objects made of a polyolefin polymer by printing a graphic representation on a face of a first film made of a stretched polyolefin polymer, associating the first film with a second film having a lower melting point than that of the first film, in order to obtain a membrane formed by the associated first and second films containing the graphic representation between them. The membrane is transferred into an injection mold and a polyolefin polymer is injected into the mold for forming the object, thereby obtaining at least a partial melting of the second film so that the membrane forms one body with the object.

Abstract: Methods have been invented for molding parts and for embedding a decorative, instructional or identifying pattern into the surface of molded products during a molding process. In certain embodiments of this method, the pattern is formed as a pattern structure consisting of one or more shaped film elements or of many complementary shaped elements of various opaque, translucent, and/or transparent films. Inks, paints, overlays and inlays may be used on one or more of the films to further embellish the pattern structure. The pattern structure is then applied to the inner surface of a molding mold. In a rotomolding process according this invention, the mold is charged with casting resin, heated and rotated. The pattern structure is molded into and becomes an integral part of the product.

Abstract: A process for manufacturing a multilayered object by molding having the steps of positioning a sheet of thermoplastic or textile material in a mold, injecting thermoplastic resin under the sheet, and forming the object by compressing the sheet and the resin. A screen is interposed between the sheet and the thermoplastic resin. The permeability of the sheet is a function of the resin and of the compression. An incision of the sheet is formed in the area of the outer face of the sheet.

Abstract: In the assembly of a windshield glass and a weather strip having a partly modified cross section the weather strip is extruded along the peripheral edge of the windshield glass and fixedly adhered thereto, a movable die 132 of a die assembly is properly moved so as to change the shape of an orifice of the die assembly.

Abstract: A method and apparatus is disclosed for forming a cover for an air bag deployment opening, the cover having a tear seam defined by a reduction in thickness of the cover. The cover can be formed as an unitary part of an outer skin layer for an automobile interior trim structure. The apparatus includes a thin shell having an inner surface upon which a thermoplastic material is cast to form the outer skin. A multiplicity of pins are disposed on and extend away from a backside thereof to transfer heat to the inner surface. The density of the pins is reduced on the portion of the backside of the shell proximate the portion of the inner surface upon which the tear seam of the outer skin is to be formed. The shell can be heated or cooled by using a plurality of nozzles to impinge heated or cooled air onto predetermined locations of the backside. A cover and tear seam construction is also disclosed.

Abstract: A process for cleaning a surface of a refractory structure which is at an elevated temperature, including projecting against the surface a comburent gas stream which is a powder stream including fuel particles carried in an oxygen-containing carrier gas the comburent gas stream impinging upon the surface at an impingement zone, whereby the fuel particles are caused or allowed to burn in a reaction zone defined generally around the impingement zone and the heat generated by the combustion of the fuel particles causes the surface or material adhered thereto to melt and provide a melted material, and projecting a scouring stream including oxygen simultaneously or alternately at the surface to scour the surface in the vicinity of the reaction zone and thereby clean the surface due to the scouring stream blowing away the melted material.

Abstract: A process for making decorative articles. The process includes heating a polymeric substance up to its glass transition temperature and stretching in at least one direction from a first size to a second size. The substance is allowed to cool in the stretched condition. The stretched polymeric substance is thereafter heated locally at an intensity until surface cracks appear therein to a desired depth. The interior area of the cracks in the polymeric substance is then treated in various ways. Finally, the polymeric substance is heated further until the polymeric substance begins to retreat to its original dimensions and the cracks close.

Abstract: A mold apparatus and method for forming encapsulated glass which includes the use of a plurality of mold sections 10 and 12 which, when closed, cooperate with a sheet 5 and at least one seal 25 to define a gasket forming cavity 35. When a gasket forming material is injected into the gasket forming cavity 35 and is allowed to at least partially cure, a gasket 2 is formed on at least a portion of the sheet 5 to produce a window gasket assembly 50. A seal 25 with an outwardly angled facing portion 27 defines an interior face 37 of the gasket forming cavity 35 and prevents leakage of the gasket forming material and the formation of flash on the sheet 5. In one embodiment of the invention, the mold section 12 is made of a resilient material and mold section 10 is made of a rigid material. In another embodiment of the invention, mold section 12 has positioned therewithin a rigid member 45 having a finishing surface 48 which cooperates with the seal 25 and the sheet 5 to define a gasket forming cavity 35.

Abstract: A method for making an optical fiber bundle which, in one aspect, includes bending each of a plurality of optical fibers to form a bend therein and then suspending the fibers over a suspension member; holding the fibers taut under tension; applying potting material to the fiber bends and curing it; and removing the fibers from the suspension member.

Abstract: A method of producing slab-like concrete elements having mutually parallel sides and containing one or more filling bodies wherein a part of the element which contains one or more filling bodies is cast in a first manufacturing stage and allowed to harden, and wherein the hardened part is turned upside down and lowered into a mould which contains fresh concrete, in a second manufacturing stage and the fresh concrete is allowed to harden. In the first manufacturing stage the concrete is poured into the mould to a level such that the upwardly facing side of each filling body will be free from concrete; in that the free surface of each filling body has provided therein recesses whose combined volumes correspond to the variation in the amount of concrete used in the second manufacturing stage; and in that in the second manufacturing stage the first part is lowered into the mould containing fresh concrete to a level at which the produced concrete element has a nominal thickness.

Abstract: A method and apparatus for rotationally applying polymers where the apparatus includes a rotational lining unit with a first support section rotatably secured to a main frame for rotation about a first axis, and a second support section secured to the first support section for rotation about a second axis. The second support section includes a portion for holding an enclosed structure to be lined. The unit also includes drive arrangements for driving the first and second support sections so that an enclosed structure can be held by the holding portion and rotated simultaneously about a plurality of axes.

Abstract: Method and apparatus for rotationally casting a plastic tank liner having a molded-in access fitting and for ensuring a uniform thickness of plastic in the wall of the liner and on the fitting. A hollow mold having a mold cavity surface conforming to the surface of the liner is provided. An access fitting is removeably mounted on the mold so that the interior surface of the fitting may be coated with the molding plastic and so that the molded liner and the filling may be removed from the mold as a unit. The mold is rotated about orthogonal axes while the mold is heated to a resin liquifying temperature. Additional heat is supplied to the fitting at a rate proportional to the mass of the fitting so that the temperature of the inside surface of the fitting is increased at a rate substantially corresponding to the inside surface temperature of the mold.

Abstract: A fiber reinforced thermoplastic resin shaped article is prepared by supplying a preheated fiber reinforced thermoplastic resin sheet between upper and lower molds, positioning the upper and lower molds so that a clearance between the upper and lower molds at the time of the completion of mold clamping is larger than a thickness of the unpreheated fiber reinforced thermoplastic resin sheet, and supplying a molten thermoplastic resin in a recess provided in at least one of the upper and lower molds through a resin passage provided in the mold so that a portion formed from the molten thermoplastic resin in the recess is integrated by fusion with a portion formed from the fiber reinforced thermoplastic resin sheet.

Abstract: A method for the fabrication of a composite structure made from a profile plate and concrete. The relatively lightweight steel profile plate is placed at the building site. At the building site the concrete is sprayed on the surface of the profile plate to form the composite structure. The profile plate can be sprayed with concrete, layer by layer, with each layer being allowed to at least partially set between sprayings. Thus, the inherent load-bearing capacity of the structure increases as the layers are applied and the weight of the structure increases.

Abstract: A method of producing surface features having topological variances in the scribeline areas of a wafer adjacent to the dies. Surface features are used to reduce fracturing of molding compound and to prevent movement of the molding compound with respect to the surface of a die in a plastic encapsulated integrated circuit.

Abstract: A process for renewing the refractory lining of a ladle for casting steel and of similar metallurgical vessels. While the ladle (10) is still hot, the slag (S) still adhering to the inner surface (26) is melted off from the remaining lining (2) with the aid of a high-temperature burner (9) operating under reducing conditions and allowed to run out of the ladle (10) in the molten condition. After cooling, the glassy surface of the remaining lining (2) is roughened. The new refractory lining (30) is then applied by casting, with the aid of a template.

Abstract: A method for manufacturing the half body portions of a magnetic tape cassette or the like having an image transfer layer on its outer surface. An image transfer film is placed in a molding cavity, which film includes a base layer, a matting layer, and an image transfer layer. The function of the matting layer is to roughen the surface of the image transfer layer, while allowing easy subsequent peeling therefrom. A molten plastic is injected into the molding cavity against the image transfer layer. After the resulting product solidifies, the product is removed from the molding cavity, and the base layer and matting layer are peeled from the product, leaving the image transfer layer on an outside surface of the product.

Abstract: A casting is formed by inserting a metal reinforcement coil into a mold cavity and injecting a plastic casting material into the cavity such that the coil becomes embedded within the plastic casting material. Prior to being placed in the cavity, the coil is heat treated to relieve stresses therein, and a layer of plastic is sintered to the outer surface of the coil. Plastic is injected into the mold at a temperature lower than the heat-treating temperature, but hot enough to melt an outer portion of the layer and become joined therewith. An inner portion of the layer remains sintered to the coil.

Abstract: A method for producing a unitary part having a property enhancing coating strongly bonded to a core of either plastic or fiber reinforced composite is provided by applying the coating to a formed and shaped carrier substrate which is placed into the mold. Plastic is injected into the mold such that the plastic infiltrates the coating during molding and therefore locks the coating to the part after cure. Utilizing the present method substantially enhances the coating bond strength and reduces manufacturing costs by eliminating a post production coating step.

Abstract: A process for preparing thermoinsulating and structural formal articles in which(a) a thermoplastic polymer sheet is heated at a temperature above its softening point;(b) the heated thermoplastic polymer sheet is thermoformed on a thermoinsulating foamed preform made of substantially the same polymeric material; and in which(c) prior to the thermoforming in step (b), the thermoinsulating foamed preform is cooled to prevent excessive collapse of the surface of the thermoinsulating foamed preform resulting from contact with the heated sheet.

Abstract: A method and device for producing vehicle tire bead-bead filler assemblies (2), whereby green elastomeric material is injected, by means of an externally-cooled distribution tank (38), into a number of annular chambers (22) defined by two half molds (6, 7) closed about a substantially cylindrical inner core (8); an inner portion of each chamber (22) being occupied by a respective bead (3) preassembled onto the core (8), and an outer portion (32) of each chamber (22) constituting the molding chamber of a respective bead filler (4).

Abstract: A method and device for manufacturing tire forming bladders (2), whereby a curing mold (3) defines, via first and second half molds (4, 5) and an inner core (6), an inner molding chamber (7) inside which a precured reinforcing ply (72) is optionally inserted; the mold (3) having an outer injection chamber (34) communicating with the inner chamber (7) and consisting of a variable-volume chamber of an injection cylinder (65); the outer chamber (34) being provided with a mass (35) of heated uncured rubber, which is injected into the inner chamber (7) with the mold (3) closed and, when cured, is extracted from the mold (3) by opening the inner chamber (7) and extracting the inner core (6).

Abstract: A room temperature curing polyurethane composition is bonded to the surface f cables having jackets of an olefin/ester interpolymer to provide a water resistant seal thereabout by first exposing the surface of a length of cable to an alkali metal hydroxide solution to hydrolyze the functional ester groups and thereby substitute hydroxyl groups for the organic acid of the ester in the interpolymer at the surface of the jacket. A diisocyanate primer is applied to the treated surface and it interacts with the hydroxyl groups to produce pendant reactive groups. A room temperature curing urethane prepolymer composition is then molded about the primed surface at ambient temperatures and the unreacted hydroxyl groups along the urethane prepolymer chain react with the pendant reactive groups of the jacket to produce a firmly bonded overmolding on the jacket.

Abstract: A process for producing a reinforced plastic motor vehicle bumper includes the steps of placing a woven roving (17) on a center section of a preform screen (10) that is retained by a vacuum draw from a suction fan (16). Chopped glass fibers (20) and a curable binder are sprayed onto the preform screen and woven roving. A second layer (22) of woven roving is placed onto the center section of chopped glass and first layer (17) of woven roving. Either the excess trim (39) is trimmed by a cutting die (50) before the preform is cured or the die is first cured and then the excess trim is trimmed by a cutter using a plastic base (35) in the screen that circumscribes the contoured section of the preform screen.

Abstract: A method for joining together tubular plastic products (1, 2) by heating the joint faces of the plastic products (1, 2) which have been chamfered at least partly in advance, and by passing molten plastic material into the space (4), that is formed between the opposite joint faces. The fixing of the tubular plastic products (1, 2) and the feed of the molten plastic material take place with the aid of a mold tool (5) which is applied onto the space (4), and molten plastic material is passed rapidly into the hollow space between the mold tool, (5) and the joint faces through a feed stub (6) provided in the mold tube.

Abstract: A method of producing a glass-plastic, laminated, ophthalmic lens structure in a continuous operation. A thin, flexible, plastic adhesive layer is applied to a glass element to form a composite body that is inserted in a cylindrical gasket in such manner as to fit snugly and be sealed from the ambient. A monomeric formulation is flowed onto the adhesive layer and cured to form a laminated lens blank.

Abstract: To rehabilitate an internally corroded underground pipeline, excavations are made at its opposite ends to which launching and receiving pipe structures are then secured. Various pig member sets, with appropriate treatment fluids carried thereby, are air-driven through the entire length of the pipeline to successively acid clean, etch, and neutralize its interior surface. The interior pipeline surface is then thoroughly dried by flowing dehydrated air through the pipeline. Specially designed leading and trailing extruder pigs, with 100% solid, high viscosity, solvent-free epoxy coating material therebetween, are then air-driven through the pipeline to extrude a first protective coating layer onto its interior surface. The first layer is then dried with dehydrated air.