Abstract: The present invention discloses a method for manufacturing slippery-proof foam materials having protruded threads, which comprises the steps of foaming Thermoplastic Elastomer (TPE) or EVA pellets into a foam material plate, attaching a high heat resisting mesh cloth onto the surface of the plate, heating the plate by a heating device to soften the material to an extent of being suitable for a plastic formation, rolling and pressing the plate by a rolling mold or a piece of mold having an even surface and a plurality of tiny grooves thereon, so that the section of the plate receiving a larger rolling and pressing force moves towards the section receiving a smaller rolling and pressing force, and then passes through the meshes of the high heat resisting mesh cloth under the condition of being held up by the high heat resisting mesh cloth to form evenly protruded threads on the surface thereof after being cooled immediately.

Abstract: A method for fabricating foam cored items in which the foam core is tightly encased by an outer shell. The method is particularly suited for fabricating foam collars that are located above the chine of a boat and extend longitudinally along the sides of the boat to provide stabilization for the boat during high performance maneuvering and/or provide a fendering system.

Abstract: A molded resin laminate in which the dimensional accuracy and the strength are excellent at a bent portion and a method for producing the same are provided. One, in which an average diameter of small cells existing in a region on a side of a resin cover to be formed into a surface layer is smaller than an average diameter of large cells existing in a region on a side of a base resin component to be formed into a base layer, is used as a foamed resin component to be formed into an intermediate layer of the molded resin laminate. After the base resin component is molded with a molding machine, the base resin component is held on a male mold of a forming machine different from the molding machine described above. A sheet-shaped laminate, which is obtained by joining the foamed resin component and the resin cover, is arranged between the base resin component and a female mold. Subsequently, the forming machine is subjected to mold clamping.

Abstract: A sheet-form structure of expandable thermoplastic resin is provided which is capable of undergoing a pseudo-one-dimensional expansion in its thickness direction and which enables manufacture of thermoplastic resin foams having reduced variations in thickness and weight precisions, increased compressive strength, and excellent properties such as surface smoothness. A method of manufacturing the sheet-form structure, as well as such thermoplastic resin foams, are also provided. A sheet-form structure 1 of expandable thermoplastic resin including granules 2 of expandable thermoplastic resin arranged generally uniformly for integral connection thereof through a thin film 3 of expandable thermoplastic resin.

Abstract: A method and apparatus for making a dome-shaped sealing element for a vaginal speculum from an annular workpiece of closed cell polyethylene foam sheet material is described.

Abstract: Resin or pitch is melted in a melt blender apparatus (11) and then loaded, into a heated jacketed holding tank (12). A pair of feed lines (14, 16) receives resin from the holding tank (12) and feeds an upper gear pump (15) and a lower gear pump (17). A mixing enhancement such as a static mixer (18, 19) is located in each of the feed lines (14, 16) between the gear pumps (15, 17) and the resin delivery ends (25, 26) of the feed lines. The resin-melt feed lines may be equipped with pressure indicators (27, 28, 32, 34) and pressure relief valves (23, 24). The resin-melt feed lines may also be equipped with pump accumulators (31, 33). Resin melt pressure created by the gear pumps (15, 17) forces a piston inside the accumulator back to the desired position. The accumulators (31, 33) can also be used to maintain constant pressure in the feed stock. Resin can be recycled from the accumulators (31, 33) into the melt blender (11).

Abstract: Ordered, monodisperse macroporous polymers, their corresponding ordered, monodisperse colloids, and methods of preparing them are disclosed. The methods use an ordered, monodisperse colloidal template to define the polymer pore morphology, which in turn acts as a mold for the growth of a new ordered, monodisperse colloid. The macroporous polymer may be prepared with either spherical or ellipsoidal pores from a wide variety of polymeric systems. The new ordered, monodisperse colloid may be grown from a wide variety of materials including ceramics, semiconductors, metals and polymers. These materials are potentially useful in optical, micro-filtering and drug delivery applications.

Abstract: A laminate structure for making a cushioned component for a vehicle interior, such as a seat cushion or head rest, has a high density foam bonded to an interior surface of a seat cover material. After the laminate structure is formed into a desired shape for the cushioned component, it is inserted into a vacuum mold having a mold surface with a shape corresponding with a desired exterior surface shape of the cushioned component. Liquid foam-forming material is injected into the laminate structure within the mold and allowed to cure to form the cushioned component. The high density foam of the laminate structure preferably has a density of at least 4 lbs/ft3 and an air permeability of 5 to 100 ft3/ft2 minute. This high density foam may be created by felting a polyurethane foam.

Abstract: A method for making a resilient material includes providing a particulate polymer, discrete pieces of foam, a foaming agent and a plasticizer. The polymer, foam pieces and plasticizer are mixed and disposed in a mold. The mold is heated to cause melting of the polymer without melting of the foam. After coating of the melted polymer, a heterogeneous resilient cushion is formed with gelated polymer surrounding the discrete foam pieces.

Abstract: The invention concerns the production of articles comprising at least a rigid element (1) and at least an element (2) made of a thermoplastic material obtained by moulding. The rigid element (1) has a profiled transverse section defining a concave space, wherein is positioned at least partly an element made of thermoplastic material.

Abstract: A method for manufacturing shoe components using EVA copolymer of film shape having a thickness of 0.01 to 2 mm, preferably 0.1 to 1.0 mm and a surface roughness variations which cannot be easily discriminated through touch or sight, and a shoe component manufactured by the method are provided. The method overcomes the drawbacks caused during the process of manufacturing a shoe component with different mechanical physical properties or colors. The method allows for ease of manufacture of a shoe component with two or more types of colors or physical properties, through a single foam molding process using a film with less variation and ease of processing, to thereby simplify manufacturing procedures and reduce manufacturing costs. In addition, a high quality shoe component with no additional seam-line is obtained.

Abstract: The amount of residual carbon and hydroxyl groups in a synthetic quartz powder made by a wet process is reduced by baking the synthetic quartz powder in a low pressure atmosphere. Quartz glass crucibles made using the synthetic quartz powder have low bubble contents, and are particularly suited for growing single crystals.

Abstract: A method for making a multi-layer helmet shell wherein inner and outer, structural, load-bearing semi-rigid layers are spray-deposited onto opposite surfaces of a pre-shaped, pliable viscoelastic, acceleration-rate-sensitive, microcellular foam core.

Abstract: A fiber-reinforced, polymeric implant material useful for tissue engineering, and method of making same are provided. The fibers are preferably aligned predominantly parallel to each other, but may also be aligned in a single plane. The implant material comprises a polymeric matrix, preferably a biodegradable matrix, having fibers substantially uniformly distributed therein. In preferred embodiments, porous tissue scaffolds are provided which facilitate regeneration of load-bearing tissues such as articular cartilage and bone. Non-porous fiber-reinforced implant materials are also provided herein useful as permanent implants for load-bearing sites.

Abstract: In order to make weather seals from closed cell elastomer foam material, molten plastic is extruded over a substrate of the foam material. Surface reactions during extrusion are avoided by continuously pulling the substrate through an oven chamber to degas (and remove moisture from) the material at least on its outside to a limiting thickness of the order of 10-30 mil to form a skin or crust. The extrusion of the over-coating is carried out to form a sleeve while the substrate is still hot. Since the skin is a degassed region on the outside of the foam substrate, reactions which may cause blistering and prevent the extrusion of a smooth and firmly adhering skin are avoided. The substrate material is preferably a thermosetting EPDM rubber closed cell foam, and the over coating material is a thermoplastic elastomer (TPE).

Abstract: Molten polymers are forced into T dies combined to form a multiple T die, the molten polymers are extruded through the T dies in monolayer. The monolayers extruded through the T dies are superposed and laminated outside the multiple T die while the polymers are in a molten or semi-molten state to form a intermediate molten multilayer. The multiple T die is advanced into a space between an open top half mold and a bottom half mold of a compression mold to deliver the intermediate multilayer onto the bottom half mold. The intermediate multilayer is cut to a predetermined length on the bottom half mold, and is processed for compression molding in the compression mold to form a multilayer article. A molding cycle for molding the multilayer article is carried out automatically at a remarkably improved manufacturing efficiency.

Abstract: This invention provides method for placing indicia on a support for an imaging element comprising embossing indicia, such as a logo, on a roller; providing a support wherein said support comprises a closed cell foam core and adhered thereto at least one flange layer, wherein said closed cell foam core comprises a polymer that has been expanded through the use of a blowing agent; and pressing said support against said embossed roller.

Abstract: An automobile interior trim component includes a molded substrate laminated onto a cover sheet including a foam backing and a skin film having a surface texture. The cover sheet is preheated so the skin film is in a melted viscous liquid state above its melting temperature, and the foam backing remains in a solid elastic foam state below its melting temperature. The preheated cover sheet is mechanically pre-molded by a back mold into a front mold. Pressurized air is applied through the back mold, to blow-mold the cover sheet against the front mold, so the melted skin film reproduces a surface texture of the front mold surface while the solid foam backing acts as a buffer and air barrier layer. Vacuum is applied through the front mold surface. The mold is opened, a substrate is introduced, and the back mold then molds and thermally laminates the substrate against the foam backing of the cover sheet.

Abstract: A forming method of a foam board includes a hard plastic top plate and a hard plastic bottom plate provided respectively on and under a foam board placed in a mold. In a forming process by heating, the peripheral edges of the hard plastic top and the bottom plate respectively bend downward and upward automatically and extend to stick on the peripheral side edge of the foam board and fusing and adhering with each other to make up an integral peripheral edge so as to elevate the rigidity and safety of the foam board and enable it endure grinding.

Abstract: A process is provided for producing a foamed article of a thermoplastic resin composition having a relatively thicker solid skin layer exhibiting better appearance without occurrence of a swirl mark and having a foam structure of relatively uniform foam cell size with better foam cell configuration, which is light-weighing and superior in stiffness, in an easy and efficient manner, by causing the resin composition to foam up in a cavity of a mold.

Abstract: An object constructed of a thermoplastic polymer foam is heated above the polymer softening temperature, compacted to a desired reduced volume and reduced to a temperature below the critical softening temperature for storage. On the object being subjected again to a temperature above the polymer softening temperature, it assumes its original shape and volume. The object can additionally include flexible polymer sheets, fabrics or liners.

Abstract: Provided are a method for forming a foamed polypropylene resin sheet in which draw down and waving are not caused in heating the foamed sheet and in which inferior appearance such as partial thickness and wrinkles is not produced on the product, and a foamed formed article having an excellent shape obtained from the same. The method comprises a heating step for heating and softening the foamed polypropylene resin sheet and a forming step for bringing the heated foamed polypropylene resin sheet into contact with a forming mold to form it into a prescribed shape, wherein the foamed polypropylene resin sheet has an expansion ratio of 1.1 to 6 times, an open cell rate of 70% or less and a sheet thickness of 0.5 to 5 mm; and the foamed polypropylene resin sheet described above is heated in the heating step in the state that it is supported on a tabular sheet support.

Abstract: The present invention relates to foamed thermoplastic resin moldings which can be used, for example, as food product containers which can contain retort food products, etc., household electrical appliance parts and automotive interior parts, and to a process for producing the same, said foamed thermoplastic resin molding prepared by shaping a foamed thermoplastic resin sheet, the molding comprising a general part and a thick part wherein these parts differ from each other in thickness wherein the mean expansion ratio of the thick part is not less than 1.2 times the mean expansion ratio of the general part and wherein the maximum thickness of the thick part is not less than 1.5 times the thickness of the general part.

Abstract: A forming method of a foam board includes a hard plastic top plate and a hard plastic bottom plate provided respectively on and under a foam board placed in a mold. In a forming process by heating, the peripheral edges of the hard plastic top and the bottom plate respectively bend downward and upward automatically and extend to stick on the peripheral side edge of the foam board and fusing and adhering with each other to make up an integral peripheral edge so as to elevate the rigidity and safety of the foam board and enable it endure grinding.

Abstract: This invention is directed to golf balls including one or more foamed, microcellular materials. The invention also encompasses methods of controlling or adjusting one or more material properties or the weight distribution of a golf ball, and methods of forming golf balls including such microcellular materials.

Abstract: A method for shaping a slab of polyurethane foam (80) cuts portions of the foam material from one surface. A moving patterned platform (32) is interposed in a gap formed between a compression roller (56) and a drive roller (18) and defines at least one recess (36). The slab is introduced into the gap and foam material is compressed into the recess. At least a portion of the compressed material within the recess is then cut from the surface of the slab by a blade (76) just as the slab emerges from the gap to produce a profile-cut surface with a shaped portion corresponding to the shape of the recess in the patterned platform.

Abstract: A method for manufacturing EVA outsoles includes step 1 to mix EVA and foaming agent to become a mixture; step 2 to form the mixture as mentioned in step I to be particles or semi-fluid; step 3 to accumulate the particles or the semi-fluid to have a desired weight; step 4 to put the particles or the semi-fluid having the desired weight in step 3 into a mold to form an outsole, and step 5 to trim the outsoles.

Abstract: The invention is a method of making a foam filled honeycomb core structure comprising the steps of: 1) providing a honeycomb core billet; 2) reinforcing the honeycomb core with foam; 3) placing the foam filled billet in mold having a curved mold surface; 4) creep forming the foam filled billet to the general shape of the structure by applying a load to the foam filled billet; and 5) machining the creep formed billet to the actual shape of the structure.

Abstract: The present invention aims to provide a porous resin stamp, which can repeatedly seal without supplying ink for a long period of time by beforehand soaking ink therein, and a producing method thereof. The present invention is characterized in the producing method of porous resin stamp, wherein an original that can selectively pass light through is put together with a porous resin body combined with at least phathalocyanine pigments as heating material which generate heat by light irradiated from a light source; the light is irradiated from the original side toward the surface of porous resin body; and an ink inexuding portion is formed by melting a surface layer of the porous resin body with heat of the heating material generated by the light passed through the original.

Abstract: An article of manufacture comprising an expandable sag-resistant nucleus-forming monolithic composite capable of being located within a hollow interior portion of a structural material and being expanded therein. Also, articles of manufacture comprising open-cellular structural material containing within the open-cell or cell thereof, at least one expandable sag-resistant nucleus-forming monolithic composite. The composite is desirably in the shape of a plug that is similar or close to similar to the shape of the hollow interior. In addition, there is described a process that comprises forming a pre-shaped expandable sag-resistant nucleus-forming. monolithic composite for use in reinforcing and stiffening a normally open-cellular structural material.

Abstract: A continuous process for reusing scrap polyurethane involves the following stages: Chips of thermoset polyurethane foam are supported as a bed; the bed of chips while moving is heated; the bed of chips while moving is subjected to pressure or compression; and a web is formed. The resulting material is useful in many industrial applications, including padding, gaskets, and insulation.

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 method of making an acoustic device in the form of a loudspeaker drive unit having a resonant panel-form member adapted to provide an acoustic output when excited with bending wave energy, comprising forming a resilient suspension for the panel-form member by molding and simultaneously fixing the resilient suspension to the panel-form member.

Abstract: A melamine molded foam is produced by heat-compressing a melamine foam to a thickness of {fraction (1/1.2)} to {fraction (1/12)} to cause plastic deformation and temporarily fixing the shape; the heat-compression is performed under the conditions of from 210 to 350° C. for 3 minutes or longer; the heat-compression is preferably performed at a temperature within the range of lower than the decomposition temperature of the melamine monomer by 140° C. or less; in some of such molded foams, the shape recovery in the direction of thickness with the lapse of time is observed depending upon the heat-compression conditions; and the dimensional recovery ratio is 40% or less when allowed to stand at 23° C. for 200 hours.

Abstract: A method for producing a plastic composite element, in particular an interior lining element for a motor vehicle, and such a plastic composite element.

Abstract: A molding method for protective equipment includes seven steps. A first step is to prepare a mold consisting of an upper and a lower mold respectively provided with a mold hole. A second step is to heat the mold to a preset first temperature. A third step is to place a plastic plate and a foam member in the mold. A fourth step is to move the upper mold nearer to the lower mold, and then close up the upper mold on the lower mold in a preset time for the two materials to melt. A fifth step is to heat the mold to a second temperature higher than the first temperature so that the outer surface of the two materials may melt. A sixth step is to cool the mold to a preset temperature to let the two materials cool to form a shape. The seventh step is to open the mold and take out a finished product.

Abstract: A dielectric lens which is produced by injection molding of an expandable material consisting of a synthetic resin, a foaming agent and a dielectric constant conditioner. The expandable material is injected into a cavity of a foaming mold up to at least about 80 percent by weight and at least about 100 percent by volume of the capacity of the cavity and is foamed at an expansion ratio of not more than about 1.3. During the foam molding, the surface of the foam-molded body is solidified to be a radome layer. Then, the foam-molded body is transferred from the foaming mold to a shaping mold, in which the foam-molded is cooled down naturally. Further, a fitting tab is provided integrally with the foam-molded body at the edge of the radome layer.

Abstract: The present invention provides a soft-tissue prosthesis which is formed from a tubular textile substrate and a liner. The liner is affixed to the intraluminal surface of the tubular textile portion of the soft-tissue prosthesis to form a fluid-tight barrier on the intraluminal surface of the prosthesis. The liner is preferably formed from a polymer. Thus, the soft-tissue prosthesis formed in accordance with the present invention provides the advantages of both a textile prosthesis and a polymer prosthesis.

Abstract: A method and apparatus for reducing residual gases from a foamed polymer material by subjecting the foamed polymer material to a vacuum.

Abstract: The present invention provides a thermoplastic resin-molded article comprising a thermoplastic resin functional member fused partially to a foamed sheet made of thermoplastic resin shaped in a predetermined form, as well as a process for producing the same. The thermoplastic molded article is preferably used mainly as an interior part in automobiles. According to the present invention, thermoplastic resin molded articles having less variability of the drawing strength of thermoplastic resin functional members from thermoplastic resin foamed sheets can be provided, and these used in interior parts in automobiles. Such molded articles made of thermoplastic resin can be produced efficiently according to the process of the present invention.

Abstract: A fiber-reinforced, polymeric implant material useful for tissue engineering, and method of making same are provided. The fibers are preferably aligned predominantly parallel to each other, but may also be aligned in a single plane. The implant material comprises a polymeric matrix, preferably a biodegradable matrix, having fibers substantially uniformly distributed therein. In preferred embodiments, porous tissue scaffolds are provided which facilitate regeneration of load-bearing tissues such as articular cartilage and bone. Non-porous fiber-reinforced implant materials are also provided herein useful as permanent implants for load-bearing sites.

Abstract: Method and apparatus are provided for treating (e.g., recycling) polystyrene foam scrap particulate in a manner which increases the density of the polystyrene while minimizing an amount of heat required to convert the polystyrene into densified solid polystyrene plastic (e.g., polystyrene flakes), thereby avoiding noticeable polymer degradation. The invention involves first heating polystyrene particulates to a semi-molten state in a heating zone so that polystyrene particulates coalesce. Pressure is then applied in a pressure zone to the polystyrene while the polystyrene is coalescing. The pressure is applied by a pressure mechanism which crushes the heated and softened polystyrene, and which preferably maintains the pressure on the polystyrene until the polystyrene cools below the softening temperature of the polystyrene. The pressure mechanism squeezes essentially all gases (entrained air and expansion gases) from the polystyrene, and thus precludes, e.g.

Abstract: Apparatus for extruding an elongated article comprising a die having an opening therethrough; an extruder for discharging extrudable material through said die opening; structure for rotational movement between said die and said extruder so as to provide said elongated article having a rotational profile.

Abstract: A method and apparatus for making a formed laminate (20) discloses an applicator (42) for depositing a quick reacting foamable liquid mixture (36) onto a transfer member (38) from which the reacted foam (40) and any foamable liquid mixture that has yet to react is transferred onto a flexible sheet (28). Relative movement of a pair of contoured mold surfaces (74,76) of a mold (68) toward each other compresses the flexible sheet (28) and the foam while the foam is in a transitory state (41) after substantial completion of expansion and before substantial curing has taken place such that it is still viscous. This compression provides a collapsed foam layer (30) and forms the foam as well as the flexible sheet (28) to provide the formed laminate (20). A liner (32) is also provided on the opposite side of the collapsed foam as the flexible sheet.

Abstract: A method is disclosed that makes a open cell cellular body of polyethylene resin material in non-crosslinked structure, which has a maximum degree of cell interconnection, is good in recyclability and excellent in heat resistance or resistance to heat distortion. The method includes the steps of adding 4,4′-oxy bis (benzene sulfonyl hydrazide) to a polyethylene resin material to form a foamable composition and shaping the foamable composition of polyethylene resin material, heating the shaped foamable composition of polyethylene resin material to be foamed under an atmospheric pressure to form a cellular body thereof with cells therein, and mechanically deforming the cellular body of polyethylene resin material to cause the cells therein to be interconnected, thereby producing the open cell cellular body desired. The produced continuous cellular body is rendered heat resistant by irradiating the same or the formed cellular body with a beam of electrons.

Abstract: A method for shaping a slab of compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from one surface uses a compression roller, a support surface, a blade and a moving patterned platform interposed between the compression roller and the support surface. The moving patterned platform, preferably an endless belt or a series of interconnected panels, defines at least one recess, and may define a pattern of recesses of complex or simple shapes and at various depths. When the slab of cellular polymer material is compressed between the compression roller and the support surface, a portion of the material fills the recess or recesses in the moving patterned belt. At least a portion of the compressed material within the recesses is then cut from the surface of the slab by the blade just as the slab emerges from between the compression roller and the support surface.

Abstract: An ink jet printhead has a number of nozzles each ejecting drops of ink toward a surface. Each nozzle has a nozzle chamber at least partially defined by an apertured roof portion operatively connected to an actuator such that the actuator moves the roof portion away from the surface to be printed to eject the ink. The ink jet printhead also has a projection within each nozzle for effectively dislodging any dried ink clogging the nozzle rim, hence preventing blocking of the nozzle.

Abstract: The present invention provides a hollow foamed polyolefin-based resin container comprising an inner layer and an outer layer, at least one of the inner and outer layers being formed of a foamed polyolefin-based resin sheet, wherein at least a side wall part of the container has a hollow portion between the inner and outer layer and a process for produciong the same, and the like. The hollow foamed polyolefin-based resin container can be used as containers for retorted food products and other containers.

Abstract: The inventive method comprises compressing roughly half a bun of polyimide foam at a rate of no more than 12 feet per minute from its initial height of approximately 15″, until it reaches a compressed height of no more than 2″. The compression is maintained on the bun for no more than one minute, and then released. The half-bun is then permitted to expand, and it will rebound to approximately 90-95% of its initial height. This conditioned foam may then be cut or otherwise formed into acoustical panels of varying heights and/or configurations, without worry about the ultimate shrinkage after treatment. In addition the treated half-bun may be cut into irregular shapes of more varying dimensions, up to the maximum dimension of the treated half-bun.

Abstract: A non-woven fabric laminate having stretch properties constructed using hydroentanglement methods is disclosed. The laminate is comprised of at least two layers and utilizes a foam layer as a component in the preferred embodiment, replacing conventional use of fibrous materials. A superior elastomeric fabric utilizing an open or closed cell foam layer as one element of the composite structure and as the elastic member of the fabric results in superior fabric characteristics when compared to similar hydroentangled fabrics which are constructed from fibrous materials.