Abstract: A method and apparatus for preventing board warpage during the application and curing or drying of liquid epoxies, or the like, on printed circuit boards using a clamping fixture assembly, which includes at least one clamping fixture support and at least one clamping fixture overlay. If desired, a plurality of printed circuit boards may be processed using an appropriate clamping fixture assembly. Furthermore, the clamping fixture may be constructed so a slight bow or curvature thereof can counter either a convex or concave bow or curvature of the printed circuit board.

Abstract: A method for insert-molding a plural color film laminate part and part made by the method. The method comprises preforming a film laminate and subsequently insert-molding a plastic substrate against the preformed film laminate. An improvement in traditional insert molding techniques is provided by use of a specific mold cavity structure which facilitates positioning of the film laminate transition line(s) between colors within longitudinally extending groove(s) in the part show face. According to one embodiment, the film laminate is preformed with a re-entrant edge portion which is positioned within the mold cavity such that the edge of the plastic substrate will be substantially covered. The insert molding step involves positioning the preformed film laminate in a specially configured mold cavity, closing the mold and injecting molten resin into the mold cavity against the film laminate.

Abstract: A process for forming a multilayer composite insulator includes: (a) forming an insulator precursor by orienting an insulation insert in a desired location between a first facing layer of and a layer of a polymer based blanket material; (b) closing the insulator precursor in a molding press; (c) heating the insulator precursor in the molding press to a temperature sufficiently high to soften polymer binding fiber in the polymer based blanket material and cause reshaping; and (d) cooling the insulator precursor in the molding press so as to set the insulator precursor in its molded shape and complete formation of the insulator. Other relates processes are also disclosed.

Abstract: A thin film keypad includes a retainer sheet and a plurality of keycaps molded onto keycap attachment regions on the retainer sheet such that the keys are mechanically secured to the retainer sheet. The retainer sheet is made of a thin film material, such as polycarbonate or polyester, and each keycap attachment region includes at least a hole and/or at least one retainer anchor portion. The keycaps are molded from a plastic material, such as polycarbonate or polyester, ABS or a polycarbonate/ABS blend. The thin film material is placed in a molding tool and the plastic material is injected into a keycap mold cavity such that the plastic material flows through the holes and/or around the retainer anchor portions, thereby anchoring the keycaps to the retainer sheet.

Abstract: Fuel system components for vehicles may be made from polyethylene components which are typically blow molded. To inhibit fuel vapour permeation, the polyethylene is often co-extruded into a parison with the parison comprising a barrier layer. Upon trimming flash or in the mold closure itself, the barrier layer may be ruptured. Sealing of areas of discontinuity in the fuel system component to inhibit hydrocarbon vapour pass through is achieved by sealing the area of barrier discontinuity with a sealing bead which has the necessary barrier properties. The barrier properties may be inherent in the sealing bead material or in a barrier layer extruded into the sealing bead.

Abstract: A film of a plastic material fusible with a lens-forming material and having a high light transmissivity is bonded and laminated, with an adhesive, to a polarizing sheet having a polarization coefficient of 99.0% or higher and a light transmissivity of 40% or higher. The resultant laminate is hot-pressed into a shape similar to an aimed lens. The hot-pressed laminate is placed in a lens forming mold cavity, and a lens-forming resin which has been colored or of which light transmissivity has been adjusted to a desired transmissivity is injected into the cavity to thereby form a polarized lens.

Abstract: Shape memory alloy and elastically self-expanding endoluminal stents which are at least partially encapsulated in a substantially monolithic expanded polytetrafluorethylene (“ePTFE”) covering. An endoluminal stent, which has a reduced diametric dimension for endoluminal delivery and a larger in vivo final diametric diameter is encapsulated in an ePTFE covering which circumferentially covers both the luminal and abluminal walls along at least a portion of the longitudinal extent of the endoluminal stent. The endoluminal stent is fabricated from a shape memory alloy which exhibits either shape memory or pseudoelastic properties or from an elastic material having an inherent spring tension.

Abstract: A method of manufacturing a vehicle pull handle assembly includes injection molding a pull strap portion in the first shot of a multi-shot molding process. The pull strap portion includes a first pivot joint member. A base is over-molded onto the pull strap portion in the second shot of the multi-shot molding process. The base includes a second pivot joint member which pivotally mates with the first pivot joint member but does not chemically bond with the first pivot joint member in the final molded pull handle assembly.

Abstract: The invention relates to a method for linking a first plastic component (6) with a second plastic component (9). According to the inventive method, the first component (6) is introduced into an injection mold with at least one connecting section (12) at which the link with the second component (9) is to be established. The second component (9) is formed by injection-molding plastic material onto the connecting section. A surface of the connecting section (12) is at least partially covered by the plastic material of the second component (9). At least one of the components may consist of a plastic material that requires only a relatively narrow temperature range to be moldable in the molten state. At least one binder body is formed at the surface intended to be covered by the injection-molded plastic material which binder is firmly linked with the surface. Said binder melts when contacted with the heat energy of the injection-molded plastic material and fuses with the injection-molded plastic.

Abstract: A method is described for the back-moulding of sheets (7) with thermoplastics, in particular of printed sheets to protect the decorated surface against scratching or detachment, in which a sheet (7) that is initially separated from the moulded-article wall is pressed against the moulded-article wall by the melt front (3).

Abstract: A mold to make a plastics material piece includes two parts defining a cavity corresponding to the piece to be made, each part has a peripheral zone for coming into contact with the other part's peripheral zone to define the mold's joint face. One part is made up of two blocks, namely a central block and a peripheral block, the two blocks suitable for sliding relative to each other in the mold closure direction, and the peripheral block capable of movement so as to move the peripheral zone away from the edges of the sheet. A method of making a plastics material piece includes placing a sheet in a part of a mold, moving a peripheral block, closing the mold, and moving the peripheral block to a molding position while keeping the first and second peripheral zones in contact.

Abstract: The present invention generally relates to interior trim parts such as door panels that are attached to an interior sheet in a motor vehicle. In accordance with the preferred embodiment of the present invention, a method of forming the trim part having an outer surface and an inner surface is disclosed. The method comprises providing a substrate having a first side and a second side and disposing the substrate in a molding tool, the molding tool has an upper mold and a lower mold. Engaging the first side of the substrate with the upper mold and the second side of the substrate with the lower mold. The first side is subject to compression molding such that the first side forms the outer surface of the trim part and injection molding an attachment surface to the second side of the substrate.

Abstract: A dual component molding assembly for packaging hot melt adhesives wherein a mold, preferably in the form of an open top pan, includes a cavity which is lined with a thin film of plastic material. The mold has openings formed therein which communicate with the cavity to facilitate vacuum forming of the film to the cavity's interior surface. The second component is a carrier for the mold and is also preferably in the form of an open top pan. The carrier also includes a cavity for receiving the mold, and functions not only to support the mold when nested therein, but also to act as a heat sink to effectively and rapidly remove, dissipate or absorb the heat from molten adhesive dispensed into the mold. After filling the mold with a mass of adhesive, the exposed open top surface of the adhesive is covered with a second layer of thin film of plastic material which is then sealed to the first film lining the interior of the mold.

Abstract: A cellular phone top cover includes a foil-decorating film (1) including an uppermost layer comprised of a transparent base film (3) and, laminated thereon, a symbol layer (6) for displaying characters or symbols and a colored layer (7) defining a transparent display window (21) of a cellular phone display, and a transparent adhesive layer (15) laminated thereon. The foil-decorating film is bonded via the adhesive layer (15) to a transparent resin molded article (17) of a cellular phone top cover shape having a voice output through-hole (22) and push button through-holes (23), and the foil-decorating film (1) on at least the voice output through-hole (22) has been removed.

Abstract: A system for producing composite or bonded metal components including: first and second pressure chambers, each pressure chamber having an elastically deformable chamber wall; means for circulating fluid at an elevated temperature and pressure through each said pressure chamber; and at least one mould assembly including at least one separate mould section providing a mould cavity within which a composite or bonded metal lay-up can be located; wherein when the system is in use, the pressure chambers are held together with the elastically deformable chamber walls located in opposing relation, the at least one mould assembly containing a said lay-up being accomodated between the chamber walls while fluid at elevated temperature and pressure is circulated through each pressure chamber such that the lay-up can be compressed and cured or formed.

Abstract: The invention provides a method of manufacturing a reinforced plastics material part from a drapable sheet (6) by means of a mold (1) comprising a first portion (2) and a second portion (3) that are movable relative to each other. The method comprises the following steps: placing the sheet on the first portion (2) of the open mold; pressing the sheet (6) against said first portion (2) at one or more locations by means of one or more pushers (8) mounted on the second portion (3) of the mold and movable relative to said second portion; closing the mold (1) and compacting the sheet (6); and trimming the portion of the sheet that projects from the join plane (15) after the mold (1) has been closed, and unmolding the part.

Abstract: The invention relates to a method for producing a hybrid frame (1) or hybrid housing. According to said method, a leadframe (3) with soldering and/or bonding tags (3a), made from a plated strip, is placed into an injection mould and moulded with plastic in order to form a housing part (2) of the hybrid frame or the hybrid housing (1). According to the invention, the soldering and/or bonding tags (3a) of the leadframe (3) are kept in the injection moulding die at least during part of the injection-moulding process, by means of a plunger.

Abstract: A process for the hot moulding of articles (L) made of thermoplastic material includes the steps of: heating at least one plate of thermoplastic material (L) to a plasticizing temperature; compressing the heated plate (L) between two moulding surfaces (14, 16), set opposite one another, of a pair of half-moulds (10, 12); and forming, by injection moulding, at least one component (22) anchored to a surface of the plate (L), while the plate is being compressed between the moulding surfaces (14, 16).

Abstract: A method of using a multi-purpose processing apparatus for simultaneously performing an injection molding operation and a cutting/forming operation. The multi-purpose apparatus places a forming operation into unused space within the injection molding machine, thereby utilizing the already present injection molding clamping pressure to pressure form parts. The apparatus results in a method that combines the three steps of forming, cutting, and injection molding into one continuous operation performed within the injection molding machine, as well as eliminating the need for numerous pre-injection molding steps.

Abstract: A process for the production by a moulding process of a micro-cellular or non-cellular elastomeric polyurethane skin layer or, more generally, to a process for the production of a composite comprising a first layer shaped part, which is made by a moulding process from a polyurethane reaction mixture, and a second layer shaped part which is adhered to the first part to form the composite. In order to avoid the use of release agents on the back side of the first layer shaped part, and thus the negative effect on the adhesion of the second layer shaped part, and the penetration of reaction mixture on this back side between the slides (9-10) of the mould, the mould surface (4) is covered on the back side of the moulding with a removable flexible covering, such as a film (12) or a membrane, with a removable rigid pre-shaped covering or with a permanent non-stick coating layer.

Abstract: Plastic panels which are useful as automotive interior trim panels, interior door panels and the like decorative and structural panels, are made by a method which provides an underturned edge onto the panel. The method includes positioning blanks into a mold cavity over top of a mold ring. The blanks are secured to the mold ring and the blank is secured to the mold cavity via a vacuum. The two piece mold is mated together and a substrate is injected into the mold cavity. The cavity is opened, the ring is lifted and the formed part is removed from the mold.

Abstract: A principal object of the present invention is to provide a method for manufacturing a filter element having a resin-molded frame, which permits to easily form the resin-molded frame, even when the filter has a complicated shape. The above-mentioned object can be achieved by providing the method for manufacturing the filter element, which is characterized by comprising the steps of: semi-curing resin in a prescribed shape to prepare a semi-cured resin; inserting forcedly at least one part of a filter into the semi-cured resin; and curing the semi-cured resin into which the at least one part of the filter has been forcedly inserted.

Abstract: A method and arrangement of bonding a film applique to a molded item produces a bright, textured and/or colored surface on a resin transfer molded item. The film is vacuum formed and placed into a female cavity of a mold. The film bonds to the molded item during the resin injection and solidification steps.

Abstract: A molded article having a curved surface is formed from a heat curable reactive thermoset polymer resin powder containing an integrally formed insert bonded therein. The integrally formed insert may be threaded for subsequent attachment of the molded article to a frame or structure. The insert is partially surrounded by a boss with supporting features to ensure that the insert is orthogonally supported.

Abstract: A process is provided for manufacturing an imbedded flooring product having a skeletal frame in the form of a mesh at least partially imbedded into a vinyl sheet substrate. The method provides for the mesh to create a pattern visible from above the sheet.

Abstract: A method for making a hockey stick shaft by a double pressing process, and an apparatus for making the same. The double pressing process consists of pulling resin soaked rovings through heated mold cavities. A core is inserted between upper and lower rovings, the press is closed, and upper and lower laminates are molded on simultaneously, using heat and pressure. The hockey stick shaft made therefrom has two opposite surfaces, each of the surfaces being provided with a fiberglass roving reinforcement along each opposite edge and a graphite roving reinforcement fiber between the two fiberglass roving means.

Abstract: A mold apparatus and method for forming a shaped laminate in one step are provided where the laminate includes a cladding layer and a foam backing layer. The apparatus includes a male mold half matable to a female mold half that define a mold cavity. An inlet is mounted on the mold apparatus for introducing foamable materials into the mold cavity. Edge folding members, carried by one of the mold halves, movable from a retracted position to an extended position, fold the cladding layer over at least part of the edge of the foam backing layer. Trim blades are located adjacent to the edge folding members movable from a retracted position adjacent the cavity to an extended position engaging the other mold half to sever the cladding layer to define the finished shape of the laminate.

Abstract: In an automobile interior component which is upholstered in a side-panel of a vehicle and its manufacturing method, in order to suppress the generation of sharp edged fragments in a collision for improving safety for vehicle occupants, high-impact-resistant core members with a rubber base ingredient are placed in an impact area and an interference area to interfere with other parts of the interior component. This avoids sharp-edged fragments being generated in a collision because of ductile breakdown of the high-impact-resistant core members enabling increased shock absorbing function and the use of inexpensive surface skin members as well.

Abstract: A method and system for co-molding a thermoplastic material with a thermoplastic sandwich material to form a thermoplastic sandwich article having a thermoplastic inner portion are provided. An inner male die forces the thermoplastic composite material and the sandwich material within the peripheral edge portion together at a temperature and pressure sufficient to fuse the materials together to form a thermoplastic composite inner portion of the sandwich material.

Abstract: A method and system for molding thermoplastic sandwich material to form a deep-drawn article utilizing a unique clamping technique and mechanism are described. The method includes the steps of positioning a blank of thermoplastic sandwich material having a cellular core over a female die having an article-defining cavity defined by inner surfaces of the female die. Then, an inner portion of the blank is forced into the female die along a substantially vertical axis and against the inner surfaces of the female die to obtain deep-drawn material. During the step of forcing at least one outer portion of the blank immediately adjacent the female die is clamped to guide the at least one outer portion of the blank to travel into the article-defining cavity at an acute angle with respect to the vertical axis. Thickness of at least one side wall of the deep-drawn material is substantially the same as thickness of the blank of thermoplastic sandwich material.

Abstract: In an air passage switching door, a packing material having a size approximately corresponding to a plate surface of a door base member is used, and the door base member is crossed with the packing material at a portion around a rotation shaft for rotating the door base member, so that both plate portions of the door base member are bonded to opposite surfaces of the packing material at different areas of the packing material. Accordingly, the air passage switching door can be manufactured using the single packing material.

Abstract: A mill blank assembly for a dental prosthesis includes a milling section and a support section for supporting the assembly in a milling machine. In certain embodiments, the milling section is adhesively bonded to the support section by a direct chemical bond that provides enhanced resistance to unintentional detachment of the milling section from the support section during a subsequent machining operation. Optionally, the support section includes a passageway that receives a quantity of flowable dental restorative material used to make the milling section, such that the restorative material that is located in the passageway provides additional resistance when hardened to unintentional detachment of the milling section from the support section.

Abstract: An elastomeric valve stem seal component is adapted for installation over a valve guide of an internal combustion engine. The seal component incorporates fabric reinforcement within an annular jacket body of the component. In one preferred form, the fabric is positioned intermediate two elastomeric layers of the seal body; i.e. between an inner layer and an outer layer. One preferred manufacturing method provides extrusion of a tube having a fabric reinforcement layer already provided between inner and outer layers. A cutting die incorporates a push ring adapted to move the component along a staged molding assembly process. A series of threaded core pins are utilized for conveyance of the component in the fabrication process, which includes extruding a rubber tube and cover over a series of threaded core pins, cutting a portion of the rubber tube to a predetermined length, and molding the predetermined length to produce the component.

Abstract: A film of a plastic material fusible with a lens-forming material and having a high light transmissivity is bonded and laminated, with an adhesive, to a polarizing sheet having a polarization coefficient of 99.0% or higher and a light transmissivity of 40% or higher. The resultant laminate is hot-pressed into a shape similar to an aimed lens. The hot-pressed laminate is placed in a lens forming mold cavity, and a lens-forming resin which has been colored or of which light transmissivity has been adjusted to a desired transmissivity is injected into the cavity to thereby form a polarized lens.

Abstract: The present invention concerns a composite article having joined ultrahigh molecular weight polyethylene and melt-flowable polyethylene portions and method of making the same. The ultrahigh molecular weight polyethylene portion has a textured surface with a pattern of ribs which may vary in shape and configuration, such as a series of parallel ribs or a plurality of pins of various cross-sectional shapes, e.g., oval, round or rectangles. The melt-flowable polyethylene portion is melt-bonded to or fused to the ribs of the ultrahigh molecular weight polyethylene portion providing high bond strengths between the two portions. In the method of the invention, a ultrahigh molecular weight polyethylene portion having a rib surface is contacted with molten, melt-flowable polyethylene. The molten, melt-flowable polyethylene is at a sufficient temperature that the temperature of the ribs is raised quickly to a temperature enabling the melt-flowable polyethylene to strongly melt-bond to the ribbed surface.

Abstract: Improved lifter (32) for injection molding apparatus and method of use thereof are disclosed. To inhibit the unsightly blemishes that may be formed in plastic parts wherein the lifter (32) comprises a leading edge (44) that is perpendicularly oriented relative to the longitudinal axis of the molded part, a lifter plate is provided wherein the leading edge (44) thereof is obliquely angled relative to the longitudinal axis of the molded part.

Abstract: A process and a device produces an assembly linkage on a hollow profile which is shaped for the installation of the assembly part by internal high-pressure remodeling. In order to achieve the shaping of an assembly linkage in a component space-saving, for a subsequent assembly correctly positioned, and with regard to its contour exactly fitted to the assembly part, in simple manner and even with high degrees of remodeling in a secure process, the hollow profile, under internal pressure, which is smaller than the remodeling pressure, is indented at the place of the to-be-produced assembly linkage by a die and by forming a rough contour. Afterward, while the die remains in this indenting position, a fluid high pressure is created in the hollow profile. Thereby, the hollow profile sides surrounding the die are molded to the external contour of the die, and that after releasing the fluid high pressure and the subsequent removal of the die, the finished trough-shaped assembly linkage is released.

Abstract: When manufacturing a foil-wrapped breast prosthesis with a filling consisting of a curable compound, the curing is performed after placing a filled prosthesis bag formed by two joined foil sheets in a mould cavity without closing the mould cavity and maintaining vacuum at least in the beginning of the curing, whereby especially an increased degree of freedom is obtained with respect to shaping the rear side of the prosthesis, so that this, among other things, can be provided with thin edge parts for obtaining good fitting to the body. To ease the mounting of the bag and the accurate positioning of this in the mould cavity, the latter is formed in a first mould part of a shaping tool, which furthermore comprises a tightening frame having a packing, which provides an unambiguously oriented tightening of the bag when this is placed in the mould cavity.

Abstract: The present invention provides a method for producing a multilayer molded article comprising a step of supplying a skin material having at least a foam layer between a pair of a male mold half and a female mold half, supplying a molten thermoplastic resin between the skin material and the molding surface of one of the male mold half and the female mold half, a step of laminating the skin material onto at least a part of the surface of a substrate made from the thermoplastic resin and a step of forming a recess in the skin material laminating region, wherein the thickness, t (mm), of the foam layer in the skin material before molding is 0.6 R or less wherein R represents the minimum radius (mm) of the recess on the skin material laminating side of the substrate in the skin material laminating region of the multilayer molded article.

Abstract: A pierceable stopper for a liquid container, which has a pierceable part made of a thermoplastic synthetic resin elastic material. The pierceable part is formed so as to prevent leakage of liquid from the container when it is pierced with a hollow needle. The pierceable part is confined in a compressed state in the stopper body of the pierceable stopper. A molten thermoplastic synthetic resin elastic material is injected into an injection mold at an injection pressure higher than the normal injection pressure to mold the pierceable part.

Abstract: A method of producing a composite plastic molded article having at least one layer of web material and a plastic body, includes placement of the web material between mold halves of an injection mold and deforming the web material through closing of the mold. Subsequently, negative pressure is applied on one side of the web material and/or excess pressure is applied on its other side, so that the web material bears upon a mold half. Plastic mass is then introduced into the opening mold in such a way that the feed rate of the plastic mass and the opening speed of the injection mold are coordinated with each other. Once a certain opening gap has been reached, the mold is closed and the plastic article is embossed.

Abstract: An insert for a combustion head gasket seals a coolant or oil aperture. The insert is manufactured separately from the main gasket structure, and is formed of two materials, a metallic body and an elastomeric sealing bead bonded thereto. A disclosed method for manufacturing the insert includes shaping the insert body and molding the bead in a single process. The method includes the steps of: (a) providing a mold having an upper section and a lower section, the lower section defining a cavity adapted to receive a blank metal substrate; (b) placing the metal substrate into the mold cavity; (c) closing the upper section against the substrate to hold the insert in place under a first applied force; (d) applying a second force greater than the first to shape the insert; (e) supplying elastomeric material to predetermined selected portions of the blank metal substrate; and (f) curing the elastomeric material.

Abstract: A method and apparatus for preventing board warpage during the application and curing or drying of liquid epoxies, or the like, on printed circuit boards using a clamping fixture assembly, which includes at least one clamping fixture support and at least one clamping fixture overlay. If desired, a plurality of printed circuit boards may be processed using an appropriate clamping fixture assembly. Furthermore, the clamping fixture may be constructed so a slight bow or curvature thereof can counter either a convex or concave bow or curvature of the printed circuit board.

Abstract: The invention relates to a process for manufacturing a thermoplastic part (1) with an injected seal (3) as well as to an injection molding apparatus and a corresponding thermoplastic part. For injecting the seal, a groove (2) is formed during molding of the thermoplastic part (1) in which groove liquid crosslinked plastic as material for the seal (3) is injected. Sealing projections (12) are formed on the groove edge and/or on the injection mold in order to prevent an overflowing beyond the groove edges during injection. When closing the mold, undercuts (6) are formed on the upper edge of the groove for holding the solidified seal (3) in the groove.

Abstract: The present process includes a mold for producing a thermoplastic resin molded article, comprising paired sliding female and male mold members, which mutually slide at the time of mold closing. A product-forming portion and a non-product-forming portion are provided in the cavity of the mold, the mold further including a resin-supplying opening. A gate portion located at a boundary between the product-forming portion and non-product-forming portion interconnects the two portions. At closing of the mold, the width of the gate at the product-forming side is less than the thickness of the formed product, and stepwise or continuously widens toward the non-product-forming side. Using this mold, a thermoplastic resin molded article, with or without a laminated skin material, can be molded in good efficiency and low cost, further having a non-product-forming portion, which can be readily trimmed from the product-forming portion.

Abstract: A method of construction a shoe is provided wherein the shoe includes an upper, a lower attached to the upper, and an outsole attached to the lower. In one embodiment, the outsole has a ground contacting surface which includes a first section and a second section, with the first section being formed of a first material and the second section having an outer later formed of a fabric material. The first section is formed free of the fabric material and is instead formed of other suitable materials, such as rubber, leather, etc. Preferably, the first and second sections are formed using a molding process.

Abstract: A method of constructing large, unitary, fiber-reinforced Polymer composite containers using a vacuum assisted resin transfer molding process. The method allows for the construction of container systems with only two separately molded parts—an open box consisting of a base (i.e., floor), 2 sidewalls and 2 endwalls, and a cover (i.e., roof). The method results in a structure which maintains the continuity of the reinforcement fibers across the junction between the floor, side, and end walls corners. This method can be applied to very large composite structures such as railcar bodies, intermodal containers, and shelters.

Abstract: The invention relates to a method for producing a two-chamber tube with a dividing wall (9) that extends into the tube head.

Abstract: A method for the manufacture of a housing (1) for an electrical connection system between parts that can be rotated with respect to each other, in particular between a steering wheel and a steering column, comprising a stationary housing part (3) and a housing part (4) which can be rotated relative with respect thereto, each of housing parts supporting a connector unit (10) and enclosing a spirally wound flexible electrical conductor (6) connected on its ends with connector units (10). The internal axial boundary surfaces (8) of the housing parts (3, 4) are provided with an insulating material (9). The insulating material (9) is a plastic material exhibiting sound-absorbing properties and is extrusion-coated on the internal axial boundary surfaces (8) of the plastic injection-molded housing parts (3, 4).

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.