Abstract: A method for making a plate-like fibre-reinforced product to be used as building or packing material, the method comprising: placing fibres on a lower laminate; applying a binding agent on the fibres so that the fibres are surrounded by the binding agent; transferring the fibres with binding agent between the lower laminate and an upper laminate between lower and upper rotating pressing plates (4, 3); allowing the binding agent to foam up, expand and harden between the upper and lower pressing plates. In order to economically manufacture such a product with desired physical and mechanical properties, the method comprises the steps according to which the fibres are made into a three-dimensional cohesive fibre mat of fibres bound together, the fibre mat having a moisture content of 5% at the most before the binding agent is applied onto the fibre mat, the binding agent is applied onto the fibre mat and the obtained mixture is subjected to a pressure of at least 0.

Abstract: The invention provides a termination for a wire rope made by a process of inserting one end of a wire rope into a mold and placing a crucible with a crucible opening over the mold. The mold opening is in fluid communication with the crucible opening. Exothermic metallic material is added to the crucible. The exothermic metallic material is ignited forming a molten material. The molten material flows into the mold around the wire rope forming a termination capable of sustaining a higher break force than the wire rope. The invention also provides a termination for a wire rope made by a process with an adhesive. The termination provides a socket for connecting wire rope to various types of equipment. The socket can include one or more frustroconical wedges for securely holding the wire rope and the termination in the connector. The socket body can also include a protection sled and various ways to connect to the equipment.

Abstract: The method for making a termination for a wire rope entails inserting a first end of the wire rope end into a mold, wherein the mold comprises a mold opening; placing a crucible on the mold, adding a separator to the crucible over an opening in the crucible, adding an exothermic metallic material to a crucible, igniting the exothermic metallic material to form a molten material that liquefies the separator; flowing the liquefied separator onto the end of the wire rope forming a termination capable of sustaining a higher break force than the wire rope. Other embodiments of the method entail using a liquid adhesive to form the termination.

Abstract: Molded structures, methods of and apparatus for producing the molded structures are provided. At least a portion of the surface features for the molds are formed from multilayer electrochemically fabricated structures (e.g. fabricated by the EFAB™ formation process), and typically contain features having resolutions within the 1 to 100 ?m range. The layered structure is combined with other mold components, as necessary, and a molding material is injected into the mold and hardened. The layered structure is removed (e.g. by etching) along with any other mold components to yield the molded article. In some embodiments portions of the layered structure remain in the molded article and in other embodiments an additional molding material is added after a partial or complete removal of the layered structure.

Abstract: A method of making a sponge device is provided. This method includes introducing a curable liquid sponge forming material into a form, placing a handle into the material before it is fully cured, heating the form to cure the material, removing the cured material from the form, and rinsing the cured material. Another aspect of the present invention is the assembly for making this sponge device. This assembly includes a runner for joining a plurality of handles, plates that are spring-biased together to support the handles, a chase formed of heat conductive metal having a shelf where the plates can be set, and a silicone form having a plurality of cavities therein for receiving the sponge forming material.

Abstract: A thermoforming apparatus having a mold with an internal vacuum chamber and a quench for cooling a thermoplastic sheet while it remains on the mold. Because the quench cools the sheet, conventional cooling lines are eliminated from the mold. A preferred process of using the thermoforming apparatus includes drawing a heated sheet over the mold, creating a partial vacuum in the vacuum chamber of the mold to maintain the sheet on the mold and quenching the sheet on the mold in a quenching tank. A preferred process of manufacturing a mold with an interior vacuum chamber includes forming an impression of the mold in a casting media, suspending a vacuum line or vacuum cabinet within the impression and pouring molten material around the vacuum line or vacuum cabinet to form the mold at least partially surrounding the vacuum line or vacuum cabinet. Vacuum holes are drilled through the mold from the mold face to the vacuum chamber.

Abstract: A process is provided for producing an insulating system, comprising at least a vacuum insulating panel (20; 30) in a matrix of homogeneous polymeric foam (602; 707), inside an interspace (101; 703) of a device which must subsequently be subjected, at least at the interspace, to a temperature higher than 100° C., without damaging this system and without causing it to lose its original insulating properties, by providing a flexible protection system of cardboard.

Abstract: A novel composition useful for golf ball covers that comprises a blend of a dilsocyanate/polyol polyurethane prepolymer with a curing agent comprising a blend of slow-reacting diamine with a fast-reacting diamine such as dimethylthio 2,4-toluenediamine and diethyl 2,4-toluenediamine, respectively. A golf ball cover made with this composition exhibits the characteristic feel and playability of a balata cover with superior durability characteristics (cut and shear resistance) which exceed those of a balata or ionomer cover.

Abstract: A manufacturing method of a plastic laminate body, the plastic laminate body having at least one plastic laminate member that is laminated on a plastic substrate, which plastic substrate is pre-processed in advance so as to have a substantially final configuration, the manufacturing method includes softening the plastic laminate member when a transfer surface of a mold member, which is pre-processed in advance so as to have a desired configuration, is transferred to a surface of the plastic laminate member, so that an excessive part of the plastic laminate member is moved to an escape part which is pre-formed at the plastic substrate.

Abstract: An embodiment of the claimed invention includes a method of manufacturing an object. The method includes providing an object portion, providing a protrusion, forming a recess in the object portion by pressing at least a first portion of the protrusion into the object portion. In addition, a recess is formed in the object by placing material adjacent to both at least a second portion of the protrusion and at least a part of the object portion.

Abstract: The invention relates to a method for producing ceramic brake disks from a green body consisting of a sheet molding compound (SMC) having reinforcing fibers, and the ensuing pyrolysis and melt infiltration. The aim of the invention is to create a single-element green body comprising very complex inner cavities after pyrolysis. In order to achieve this, the method comprises the following steps: the green body (1) is produced from a sandwich consisting of SMC (2), a thermoplastic insert (4), and SMC (2) in one working step in a tool (5a, 5b), subjected to pressure and temperature; and the insert (4) fills the green body (1) over its entire surface and comprises openings (6) which are arranged in such a way that the upper and lower SMC layers (2) are interconnected, at least in parts.

Abstract: The present invention relates to delivery conduits used in systems that provide positive pressure ventilation therapy. In particular, the present invention relates to a sleeve that allows flexible conduits to be joined and sealed to a thermoplastic connector, allowing for gases to be supplied to the conduit. The sleeve is used in the over moulding of an end connector onto the conduit. The sleeve and method of attaching a connector to a conduit of the present invention has the advantage that it prevents the connector from loosening or breaking when the conduit is bent, pulled or stressed, which can occur in some cases where the connector is attached to the conduit using a bond, such as glue. Furthermore, the occurrences of flashing of plastic across the conduit walls will be prevented during moulding, ensuring that no air or water leakages occur within the conduit walls.

Abstract: A method for manufacturing adhesive tape that pattern and mark are easily formed thereon which includes the steps of placing a felted surface of a felt portion on the bearing portion of a lower mold, alter closing the upper mold, injecting a plastic material via high pressure to merge to the back side of the felted surface, thereby the plastic board can be integrally combined wit the back side of the felted surface to obtain the best combined strength. The plastic board can be formed with specific patterns or marks as desired, such that the adhesive tape can have a hard strip to make it easier for the user to detach, even if the user is wearing heavy gloves. In addition, a logo or mark can be formed on the adhesive tape to enhance the aesthetic effect.

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

Abstract: A grip element having a soft, compressible and deformable outer layer supported by an underlying support structure sufficiently rigid to maintain a receiving channel of the grip element in an open configuration. The support structure facilitates manipulation of the grip element and assembly of the grip element onto a hand-held article without having the outer layer collapse on itself as would occur without the support structure as a result of the soft, deformable nature of the outer layer. The grip element may be formed separately from the hand-held article on which it is to be assembled, and then positioned thereon such that the hand-held article is sold with the grip element pre-assembled thereon. If desired, the grip element may be provided separate from the hand-held article, the outer layer providing a readily compressible and deformable soft cushioning surface and the support structure facilitating insertion of the outer layer over at least a portion of a hand-held article.

Abstract: A method for fabricating a seal-integrated separator for a fuel cell is presented, with which seals can be accurately positioned and the assembling time for the fuel cells may be greatly reduced. The method comprises the steps of: providing an upper mold having a groove positioned corresponding to second and fourth seals disposed on one side of a separator body, and a lower mold having a groove positioned corresponding to first and third seals disposed on the other side of the separator body; holding the separator body between the upper mold and the lower mold; and injecting melted seal material to form the seals into each of the grooves in the upper mold and the lower mold through separate gates respectively formed in the upper and lower molds. Through this method, a seal-integrated separator having the first to fourth seals which are integrated on both sides of the separator body is fabricated.

Abstract: A calcium phosphate-synthetic resin-metal composite body produced by pressing a metal member, calcium phosphate particles (or calcium phosphate particles and a calcium phosphate block) and synthetic resin particles I, which are at least partially cross-linked in advance, uncross-linked, synthetic resin particles II while heating, the calcium phosphate particles and/or the calcium phosphate block being exposed on at least part of the surface of the composite body.

Abstract: Systems, methods and apparatuses for manufacturing dosage forms, and to dosage forms made using such systems, methods and apparatuses are provided. Novel compression, thermal cycle molding, and thermal setting molding modules are disclosed. One or more of such modules may be linked, preferably via novel transfer device, into an overall system for making dosage forms.

Abstract: A method of making a composite part including an insert and an elastomer layer that is bonded to the insert. The insert is placed in a mold and an uncured elastomer is sprayed into the mold to form a composite part. The inherent adhesive properties of the uncured elastomer is the sole mechanism for bonding the elastomer to the insert.

Abstract: The present invention relates to a composite insulation material. The composite insulation material includes a syntactic foam component and a plurality of aerogel inserts. The present invention also relates to a method of making a composite insulation material. The present invention further relates to a method for enhancing the flexibility of a solid material.

Abstract: A process and apparatus for air forming an article having a plurality of superimposed reinforced fibrous layers. The layers are formed in substantially discrete forming chambers by depositing fibrous materials on a forming surface which moves along a forming path through the chambers. A first layer is air-formed on the forming surface as the surface moves through the first forming chamber and a second layer is air-formed over the first layer as the surface moves through the second forming chamber. A reinforcing web is embedded in the article during the air-forming process.

Abstract: An electrical box for use with insulated concrete form building systems includes a main body having an electrical box cavity for housing electrical outlets, switches, and electrical connections. The insulated concrete form building systems utilize insulated forms to form concrete and the insulated forms are left in place after the concrete has been poured thereby creating an overall insulated concrete element that includes the concrete and the insulated forms. In accordance with the method and the arrangement of the invention, the electrical box includes an arrangement for attaching the electrical box to the insulated form without requiring the use of any additional fasteners.

Abstract: A film-integrated gasket comprising a resin film and an adhesive rubber layer directly molded on the resin film. The adhesive rubber layer is molded from addition reaction type silicone rubber. The adhesive rubber layer can have a reduced thickness and can prevent positional alignment failure, making it suitable for a thin seal that can be used in a fuel cell, a secondary battery, a condenser, etc. without contamination of electrolytic solution, catalyst, etc. used in the cells.

Abstract: A method (10) includes the steps of placing an insert (12) into a mold cavity (20), molding an insulating layer (30) of a homogeneous and continuous composition (28) over the insert (12). The next step includes placing the insert (12) with the insulating layer (30) into a second mold cavity (36) followed by the step of molding the part (46) of a homogeneous part composition (44) over the insert (12). The insulating layer (30) is disposed between the insert (12) and the part (46) and bonded thereto. The method (10) includes painting the part (46) wherein a paint (48) is injected into the second mold cavity (32) over the part composition (44). Flexible properties of the insulating layer (30) adapt to the differences between coefficient of thermal expansion of the part (46) and the insert (12) thereby eliminating problems of potential cracks, sink-marks, and the like.

Abstract: An object of the invention is to provide a cushion body of a seat cushion that can be easily reinforced in low cost, to provide a method for manufacturing such a cushion body and to provide an apparatus for manufacturing such a cushion body. A cushion body 10 of a seat cushion has a main part and a side part generally corresponding to a main part and a side part of the seat cushion. The cushion body 10 comprises a foamed body 11 formed in a shape generally corresponding to an outline of the cushion body 10, an air-permeable material 12 fixed to the cushion body 10 and an impregnation layer 13 that serves to reinforce a portion of the cushion body 10 where the air-permeable material 12 is fixed to the foamed body 11. The foamed body his made of cold urethane foam. The thickness of the impregnation layer 13 has a thickness that can provide a predetermined strength to reinforce a portion of the cushion body 10 where the air-permeable material 12 is fixed to the foamed body 11.

Abstract: A moldable pellet used for making high impact, non-abrasive recyclable structural composites consisting of a thermoplastic polymer or polymers, with or without fillers and additives, and a synthetic cellulosic fiber in yarn or tow form such as Rayon or Lyocell. The concentration of cellulose fiber within the pellet may vary from approximately 2–80 percent by weight or higher. This moldable pellet is suitable for molding in current molding applications such as, but not limited to, injection molding, extrusion compression molding, and compression molding.

Abstract: Molding techniques and apparatus wherein at least one adjustable edge component can be used to alter the dimensions of the mold cavity between molding operations. Also disclosed are techniques for incorporating reinforcing composite elements into molded plastic parts. Most preferably, a rotomolding technique is used to fabricate a substantially homogenous composite panel for use as a partition or bulkhead.

Abstract: A method of manufacturing a molded product comprising the steps of: providing a mold conforming to the shape of the product the mold serving to define one or more molding surfaces which are to be reproduced in an article formed via the mold; mounting in the mold an article including or forming an image comprising at least one device, logo, letter, word or words or combinations of these in such a way that most, if not all of the article lies within the mold out of contact with the or each molding surface; and injecting into the mold a supply of polymerisible material so as to immerse the article; the material, at least following polymerisation being flexible and so providing at least in part, a substantially transparent product; and withdrawing the product from the mold. Typically the step of providing product is directed to an article of footwear such as a shoe or swimming fin (also known as a flipper).

Abstract: The invention relates to the production of a hybrid component, whereby a piece of metal sheet (1) is a least partly coated with plastic by injection molding, by means of the following steps: a) placing the metal sheet (1) in one mold half of an injection mold, b) closing the injection mold, such that a first mold cavity opposite an upper side (O) of the metal sheet (1) and a second mold cavity opposite an under side (U) of the metal sheet (1) are cut off from each other, c) treatment of the upper side (O) with plastic by means of at least a first sprue (9) to produce an essentially flat coating (4) connected to the metal sheet (1) and, finally, d) treatment of the under side (U) by means of at least one second sprue (10) to produce a reinforcing structure (6) connected to the metal sheet (1).

Abstract: A plastic closure includes a closure shell having a base wall and a peripheral skirt, and a sealing liner disposed on the base wall of the closure. The sealing liner includes an outer sealing layer of resilient resin secured to the base wall within the skirt, and an inner layer of barrier resin underlying the sealing layer. The base wall and the sealing layer have opposed flat surfaces, one of which has a pocket in which the barrier resin layer is disposed. The sealing layer has a periphery that extends beyond the periphery of the barrier resin layer, so that the sealing layer completely overlies and covers the barrier layer.

Abstract: A composite pole including a structural member and a cured resin layer adjacent the structural member and defining an exterior surface. The composite pole can be manufactured by providing a mold, inserting a structural member within the mold to define a space between the structural member and the mold, filling the space between the structural member and the mold with a liquid thermosetting resin, curing the liquid thermosetting resin to define an exterior surface, and removing the cured liquid thermosetting resin and structural member from the mold. The composite pole can also be manufactured by casting a jacket onto an installed pole by applying a mold around the installed pole, filling a space between the installed pole and the mold with a liquid thermosetting resin, curing the liquid thermosetting resin to define an exterior surface, and removing the mold from around the cured liquid thermosetting resin and the installed pole.

Abstract: The present invention provides a chemical mechanical polishing pad having reduced stress windows. In addition, the present invention provides a method of forming a chemical mechanical polishing pad, the method comprising, primary annealing a window separate from a polishing pad material and providing the polishing pad material in a periphery of the primary annealed window before a predetermined quench temperature of the primary annealed window. The method further comprises secondary annealing the window and the polishing pad material together and cutting the secondary annealed window and the polishing pad material to a predetermined thickness.

Abstract: A rotor for cooling pumps is provided. The rotor is of the type which includes a core to be assembled on a shaft connected with an engine and a body, fitted in the core, provided with a plurality of radial tabs in flexible material. The core and the body with the tabs are both of a material like rubber, but with different hardness. In particular the core is made of a mixture of neoprene, nitrile, PVC and aramidic fiber. The rotor combines the features of lightness and wearproof of the rotors with a nylon core, but it is as strong and resistant as rotors with a metallic core.

Abstract: A mobile telephone having a single piece molded housing or shell includes a core assembly for supporting the functional components of the mobile telephone. The core assembly may further include ancillary hardware components such as an electrical power source, user interface input/output devices, and the like required for operation of the telephone. The single piece molded shell molded about the core assembly so that the core assembly is substantially enclosed by the shell.

Abstract: A method for manufacturing of water-proof cover for zipper tab includes taking a zipper where holes are provided on the tapes thereof at the position adjacent to one end of the tooth-chains; covering an upper mold provided with a sprue thereon and a lower mold on the holes on the tapes, and inserting a core mold in-between the groove and tooth-chains; injecting plastic from the sprue and detaching the upper and lower molds after the plastic is solidified to a desired shape, such that a decorative cover is formed at one end of the tooth-chains; and mounting a zipper tab from the upside of the tooth-chains, and stapling a stopper to each end of the combined tooth-chains. Accordingly, when the zipper is drawn upwardly, the zipper tab can be positioned inside the decorative cover, such that the connecting portion of the tooth-chains and the zipper tab can be covered by the decorative cover and therefore prevent from being wetted by rain.

Abstract: A method of foam-embedding cables, in particular for foam-embedding a steering wheel skeleton which is equipped with cables, comprises the following steps: the cable is positioned in a foaming mold; a portion of the cable, which is not to be embedded in foam, is positioned in a resealable cavity provided in the foaming mold, the cavity being sealed against the ingress of foam; the cavity and the foaming mold are closed; the foaming mold is filled with foam; and the foaming mold and the cavity are opened to remove a product produced. There is also proposed a foaming tool for performing such method.

Abstract: The present invention provides a unitary run flat tire (RFT) reinforcement using filament material that is formed into a relatively rigid shape. The reinforcement is insertable into a mold for an RFT support and can maintain the needed structural rigidity for such insertion. Further, the invention provides an RFT support that is molded and includes the RFT reinforcement. The invention also provides a wheel assembly including a tire, a rim, and an RFT support between the rim and the tire, where the support includes the RFT reinforcement. The RFT support can have a colored indicator formed or subsequently applied thereto to indicate one or more attributes of the support.

Abstract: A unitary two component article for personal hygiene, as a toothbrush, wherein the same is formed by injection molding of two differing plastic materials, which plastics do not adhesively or chemically bond to each other, thereby facilitating the manufacturing process. The two differing plastic parts of the toothbrush are mechanically connected, as by interfitting portions of the two plastic components and as by shrinking one plastic component about the other.

Abstract: A method for fabricating a protective helmet includes the steps of: (a) providing a fiber-based filler, such as a fiberglass sheeting; (b) mixing course ceramic particles into a thermoset resin; (c) impregnating the resin/ceramic particle mixture into the fiber-based filler; (d) forming or molding the impregnated fiber-based filler into a shape of a protective helmet; and (e) curing the resin mixture impregnated into the fiber-based filler. The course ceramic particles are preferably created by chopping a ceramic material. The presence of the ceramic particles in the composite helmet substantially reduces the heat reflectance of the helmet; while also reducing the overall weight of the helmet, since the ceramic material weighs less than the portion of resin material that the ceramic material is being used in place of. Finally, because the ceramic particles are course, they will not all flow to “low spots” in the helmet during the curing process.

Abstract: An improved filter element is provided. In preferred form, the filter element includes first and second end caps, with media extending therebetween. The end caps are preferably formed from foamed polyurethane, and preferably there are no outer peripheral standoff indents provided in the end caps. Each end cap preferably includes a standoff ring, spaced from an outer perimeter, positioned therein. Preferred approaches to manufacturing such elements are provided.

Abstract: The substrates of the present invention comprise a polyimide base polymer derived at least in part from non-rigid rod monomers together with optionally rigid rod monomers where the substrates are cured under low tension. The resulting polyimide materials have been found to provide advantageous properties (e.g. balanced molecular orientation, good dimensional stability, and flatness) particularly useful for electronics type applications.

Abstract: A method of manufacturing a security item comprises extruding or casting a polymer plastics substrate and, during the forming process, introducing a security thread into the substrate. The security thread is embedded to different depths in the substrate so as to generate a windowed effect.

Abstract: The toothed belt is produced in a moulding cavity, which is defined by a rotating moulding wheel and an endless moulding belt, which is also rotating. For this purpose, the moulding wheel has a channel defined by lateral cheeks, in the base of which are provided recesses, which correspond to the teeth of the toothed belt. The moulding belt surrounds the moulding wheel over a proportion of its periphery and engages the lateral cheeks at that point. The polyurethane, of which the toothed belt is to consist, is injected into the inlet of the moulding cavity. Upstream of the inlet, “lost cores” are introduced into some of the recesses in the moulding wheel corresponding to the teeth in such a manner that they are embedded all around in the polyurethane. After finishing the toothed belt the “lost cores” can be removed. Passages remain which can be used, for instance, for mounting fastening elements.

Abstract: A method for forming a composite absorbent member is provided that includes: a) extruding a first fibrous component through a first meltblowing die and intermingling pulp fibers with the first fibrous component to form a first admixture; b) extruding a second fibrous component through a second meltblowing die and intermingling pulp fibers with the second fibrous component to form a second admixture; and c) codepositing the first and second admixtures on a collecting surface so as to form a composite structure having at least a first layer and a second layer. The second layer has a higher weight percentage of pulp fibers than the first layer, and the average diameter of the pores within the second layer is smaller than the average diameter of the pores within the first layer.

Abstract: An apparatus for manufacturing an elongate composite element in undefined lengths, the composite element containing reinforcement fibers embedded in a matrix based on a composition containing a curable resin, including a vacuum chamber, rigid-walled inlet tubing, an impregnation chamber, rigid-walled transfer tubing between the vacuum chamber and the impregnation chamber, a sizing die and, downstream of the sizing die, irradiation tubes providing radiation in the ultraviolet-visible spectrum to prepolymerize the resin.

Abstract: A method for manufacturing a waste block includes forming an outer housing by compressing soil material and engaging into and compressing a waste insert in the outer housing, for allowing the waste insert to be solidly and safely retained within the outer housing, and for preventing the waste insert from polluting the outer environment. The waste block may include one or more recesses or notches or juts or bulges for engaging with each other and for stably superposing a number of waste block together.

Abstract: A filter cartridge (20) and method for making a filter cartridge (20) for removing particulates from a particulate laden fluid stream moving one direction through the filter cartridge. The filter cartridge (20) is periodically subject to cleaning fluid moving in an opposite direction to the fluid stream. The filter cartridge (20) comprises filtration media (24) formed into a tubular configuration and having a plurality of circumferentially spaced apart pleats (26). A retention device (82) to limit radial movement of the filtration media (24) when subjected to the periodical cleaning fluid and to maintain the pleats (26) in the filtration media circumferentially spaced apart when exposed up to 130 degrees Celsius. Preferably, the extrudate (144) is thermoplastic, polyester, elastomeric material and at least one additive may be present. Multiple layers of the extrudate (144) may be fused together.

Abstract: A process and equipment for manufacture of a swab article is provided wherein a stick is placed onto a conveyor, adhesive is applied to one or both ends of the stick, a portion of cotton coil is attached to the adhesive bearing end, and a shaper bar or similar means forces the cotton to assume a teardrop profile by applying force parallel to the stick, wherein the shaper bar or similar means moves in a direction perpendicular to the stick at a different rate of speed than that of the stick. Differences in the rate of speed reduce tailing of cotton normally associated with drag.

Abstract: Golf ball 1 includes a core 2 and a cover 3. The core 2 has two layers including a center 4 and a mid layer 5. The mid layer 5 is formed by covering the center 4 with two half shells comprising a rubber composition, and by compression and heating of the center 4 and half shells in a mold. The rubber composition contains solid particles dispersed therein. The solid particles have a ratio “D/T”, i.e., a ratio of the particle size D to the thickness of the mid layer T, of equal to or greater than 0.3. Upon molding, the solid particles inhibit the center 4 to approach a cavity face. Accordingly, deviation of mass of the mid layer 5 can be suppressed. The solid particles have a ratio “W/T”, i.e., a ratio of the radial width W thereof to the thickness of the mid layer T, of from 0.3 to 1.0.

Abstract: A process for effecting a coupling between a plastic material and a metal surface comprising the steps of applying a powder of an adhesive polymer composition to the metal surface; then overmoulding the metal surface with a plastic material by injection moulding; and finally applying heat to the metal surface.