Abstract: Sheet-like polyurethane moldings are produced by impregnation of porous sheets with a prepolymer containing free isocyanate groups and reversibly blocked isocyanate-reactive groups or containing free isocyanate-reactive groups and reversibly blocked isocyanate groups, and subsequent reaction of the prepolymers in a heated mold.

Abstract: A method of an integrated molding by integrally pressurizing and compressing by use of means of an upper mold and a lower mold, by use of a silicone rubber. A silicone rubber has excellent resiliency, thermal resistance, separating ability from the molds and the like. By use of a silicone rubber, a working efficiency for carrying out the integrated molding can be improved and a compressing timing can be easily taken. A method according to the invention comprises steps of: uniformly coating a mixture of a foamed urethane body on a silicone rubber horizontally held; and integrally pressurizing and compressing for a certain period by an upper mold and a lower mold. The step of uniformly coating the mixture is carried out by using a spraying technique. The silicone rubber can be attached on an inner surface of the lower mold by use of means of vacuum suction.

Abstract: A wood substitute material is formed by mixing a base polymer with wood fiber or wood flour together with a quantity of lignin and thereafter creating a molten material within a compounder and extruder. The molten material is extruded or injection molded to form the desired shape. Prior to extrusion or injection molding, a foaming agent is added to the molten mixture resulting in the creation of a variable density extruded or injection molded article. In the extrusion process, a conventional extrusion die is employed having a die passage which is significantly larger than the desired eventual size of the extruded article. The enlarged extrusion is thereafter cooled and reduced in sized through a series of vacuum sizers and a final water bath prior to cutting. The degree of foaming within the extruded article is controlled by the amount of foaming agent employed.

Abstract: A method for coating objects with silicone that includes the steps of preparing the silicone material; applying the silicone material onto a surface that is resistant to adhesion to silicone, such as an acetate film layer or the inside surface of an open air mold; allowing the silicone material to sufficiently cure to allow for bonding to an object; pressing the object against the silicone material; allowing the silicone material to bond to the outer surface of the object; and then removing the object from the surface resistant to adhesion to the silicone material.

Abstract: A method of forming a decorative surface texture on a plastic component is disclosed. A planar component, composed of PVC or other plastic material, is cut and routed according to a desired size and shape. The plastic component is then heated to a temperature and for a duration such that the upper and lower surfaces of the panel shrink and the corners or edges of the panel, as well as its cut portions, melt. This produces an antique effect on the surface of the plastic component.

Abstract: A crystalline polymer resin, such as poly(ethylene terephthalate), is heated to melting. One or more blowing agents is selected wherein at least one of the blowing agents has a boiling point greater than the glass transition temperature for the resin and less than the forming temperature, such as the temperature of the mold used to form the useful article. The blowing agent(s) and resin are combined to create a mixture with a blowing agent concentration sufficient to produce a theoretical sheet foam density of less than 0.4 g/cm.sup.3. The mixture is cooled to a temperature approaching the freezing point of the mixture, and then extruded into a substantially uniform closed cell polymer foam sheet of density less than 0.4 g/cm.sup.3. The extruded sheet is then cooled by direct contact with a cooling surface at a surface temperature below the glass transition temperature such that the blowing agent(s) condenses and the sheet has a density of greater than 0.4 g/cm.sup.

Abstract: Disclosed herein is a method for continuously producing an expansion-molded article, comprising feeding foamed particles between a belt continuously traveling along the upper surface within a passageway defined by structural members and having a rectangular form in section and a belt continuously traveling along the lower surface within the passageway, and then causing the foamed particles to successively pass through a super heated steam-feeding region and a cooling region within the passageway. The foamed particles used are foamed particles of a polyolefin resin, in which a recovery factor from compression defined by the equation (1):Recovery factor from compression (%)=V.sub.2 /V.sub.1 .times.100(1)wherein V.sub.1 is the original bulk volume of the foamed particles, and V.sub.

Abstract: An acoustic absorbing component comprising a fiber-reinforced thermoplastic resin expanded body having a percentage of void not less than 50 vol %, and a resin molded body. The fiber-reinforced thermoplastic resin expanded body is fused under a pressure to at least a part of a surface of said resin molded body.

Abstract: A composite laminate structure, and a method for its fabrication. The structure includes a syntactic core layer (10) including an epoxy system catalyzed by a Lewis acid, and two face skin layers (12), each of which has multiple graphite fibers laid up in a polycyanate matrix resin catalyzed by cobalt. After thermal curing, the laminate structure has the unusual, but highly desirable property that it is compliant enough to be conformed at room temperature to a different shape, without damage to the structure. The structure may be later conformed to other shapes or conformed to its original shape, again without damage. Structures of unusual shapes can, therefore, be easily fabricated from sheets of the laminate material formed in one (1) convenient initial shape, such as a flat panel.

Abstract: A method of manufacturing composite board whereby a continuous coat of mortar reinforced with glass cloth or a similar material is laid onto a continuous core. The still fluid mortar dribbles onto the core at a specific viscosity and is distributed over the core. The rate at which the mortar dribbles is regulated.

Abstract: A process is disclosed for producing a positive-material with a skeleton made of shell-like structures and an interconnecting pore system designed between the skeleton structures. Also disclosed is a process for producing a negative-material made of shaped bodies interconnected by bridges a process for producing a positive/negative-material, materials produced by this process and their use as bone replacement materials, implants, filters and drug delivery systems. According to this process deformable shaped bodies in bulk are poured into a mold that forms a negative model of the material.

Abstract: A process for fabricating a foamed plastic product. The process includes a plastic film that is prefoamed in order to introduce lamellar discontinuities such as prefoamed bubbles. The film is pressurized by a gas under a positive pressure causing the gas to diffuse into the film, forming a second film. Further, the second film is inflated in order to form the foamed plastic product. The second film is inflated by heating the second film at a temperature below the melting point of the second film and under a reduced pressure.

Abstract: A headliner is a laminate of multiple layers. The layers include polyurethane foam, agricultural fibers, a decorative material, and a backing. The agricultural fiber is jute, sisal, or kenaf or mixtures thereof. The method of making the headliner laminate includes making the sheet of agricultural fibers incorporating a binder, saturating a foam layer with an adhesive, putting one sheet of agricultural fibers on each side of the foam layer, applying the decorative material and backing to one side each, and squeezing the layers together to distribute the adhesive to all the layers and laminate them.

Abstract: A high speed plastic-forming process forms a curved wall section with a compound radius along the outer edge of a sheet of plastic foam material. The process includes first die cutting the flat sheet material to a shape having an initial edge curvature, followed by securing the die cut piece to a carousel which passes the curved outer edge section of sheet material past heaters that controllably heat the top and bottom surfaces of the moving curved edge section. The carousel then passes the pre-heated edge section into contact with an elongated stationary curved forming shoe along the outer edge of the carousel to progressively bend the pre-heated section into a curved wall section of compound radius. The carousel then passes the formed wall section into contact with an elongated stationary curved cooling rail extending around most of the outer edge of the carousel downstream from the forming shoe.

Abstract: Expanded or foamed plastic material is fed into a hopper containing a first auger having a cutting function. The first auger is driven by an electric motor and cuts the plastic material into pieces which are discharged from the hopper into a vertical chamber. The vertical chamber contains a second auger driven by an electric motor. The pieces of plastic material are compressed by the second auger and delivered into a chamber which serves as the inlet end of a horizontal friction chute. The plastic material in the chamber is compressed by a hydraulic ram which forces the compressed plastic material along the friction chute.

Abstract: The inventive packaging item is e.g. a tray for packing fresh meat. It has at least on its bottom part (10) grooves (11) which open towards the inside of the packaging item. The openings of these grooves are narrower than the inside part of the grooves. If the groove opening is sufficiently narrow e.g 1mm or less, unwanted liquid oozing out of the packed meat is trapped in these grooves (11) and such separated from the meat and kept out of sight of a potential buyer.

Abstract: In a method for bonding a foam-fabric composite to a molded foam core, particularly suitable for use as an automotive cushion assembly, specific advantageous polymeric MDI-based foams are used to achieve consistently excellent bond strength. In the method, a foam layer is flame laminated to a fabric layer. Then the foam-fabric laminate and an air impervious adhesive film are placed over a mold surface, and the adhesive is drawn against the foam of the foam-fabric laminate and the fabric layer is urged against the mold surface by applied vacuum. The foam core pad is placed adjacent to the adhesive film. The film is heated and diffused into the foam pad and into the foam of the foam-fabric laminate, respectively, and allowed to cure. The foam layer laminated to the fabric is formed as the reaction product of a polyether polyol or a graft polyether polyol with from about 30 to about 60 parts by weight of an MDI or a polymeric MDI/TDI blended isocyanate or mixtures thereof, from about 1.5 to 3.

Abstract: A method of making an article of footwear includes the steps of forming a foam shell for an article of footwear by wrapping a foam side wall around the periphery of a base, positioning the foam shell on a last, securing the last and the foam shell within a mold and closing the mold, applying heat and pressure to thereby mold the foam shell to the shape of the last, and then opening the mold and removing the molded article of footwear from the last. In a preferred embodiment, the method further includes the steps of forming an inner bootie, having an inner liner and a foam overlay, and inserting the inner bootie over the last prior to positioning the foam shell thereon. The inner bootie includes the inner liner with the foam overlay attached to selected regions thereof. The step of applying heat and pressure thereby includes molding the inner bootie with the foam shell to form the molded article of footwear.

Abstract: A method and an apparatus for manufacturing decorative panels with relief decorations on at least one of the broad sides of the panel are described. In a chamber, a hard, at least partly thermoplastic resin foam sheet with an essentially closed cell structure is substantially evenly heated on at least one of its broad sides, such that it becomes soft. Then, by means of a mould, the decorations in raised and/or sunken relief are applied to at least one of the broad sides by pressing.

Abstract: Improved pin-reinforced sandwich structure ties the face sheets (typically on opposite sides of a foam core) together with a plurality of Z-pins that extend into each face sheet (through the core). The pins are arranged in a tetrahedral or hat section configuration in 2-dimensional or 3-dimensional arrangements to provide enhanced reinforcement, particularly in shear. We are able to improve the pulloff strength additionally by dimpling the core surrounding the pins to produce adhesive fillets along the pins.

Abstract: A method of shaping a layer of settable material such as honeycomb core (24) including placing the core on a flexible support (38); translating the flexible support (38) and core into an oven (28); heating the core to a desired forming temperature in the oven; translating the flexible support (38) and core (24) horizontally from the oven into a forming area (26); lowering a contoured upper die (32) onto the core (24); tensioning the flexible support (38); pressing the core between the tensioned flexible support and the upper die so that the core (24) is forced to conform to the shape of the die (32); cooling the core to set temperature; and raising the die (32) to remove the finished shaped core, is provided.

Abstract: The invention pertains to a composite panel comprising a foamed thermoplastic core layer which is joined on both sides without adhesive to thermoplastic outer layers reinforced by fiberglass mats. The composite panel is used to make molded parts for motor vehicles.

Abstract: This invention concerns an injection moulding process for soles in expansible and cross-linking "EVA" based compounds characterised in that during the cooling stage of the moulded sole the spontaneous shrinkage of the same is arrested by means of a template consisting of a rigid shaped plate placed on the sole so that its edge connects with a perimeter edge realised specifically on the upper surface of the sole, whose dimensions reduce no further either during the remaining cooling phase of after cooling.

Abstract: A method for closing of the pores of selected areas of the surface of thermo-plastic porous material (7), comprising heating of selected areas of the surface of the porous material (7) by light radiation. Simultaneously, the surface of the porous material (7) is compressed by a transparent smooth body (11). According to the embodiment (I), the surface of the porous material (7) is scanned over by one of the several focused light beams, that are switched on and off. According to the embodiment (II), between the porous material (6) and the smooth transparent body (11), a transparent means containing a light-absorbing pattern (9) of surface elements with pores being left open is placed, whereas the distance between the light-absorbing surface (10) and the surface (7) of the porous material (6) is at least 0.

Abstract: In foam molding for molding a foam-molded article from a foaming material, heat is applied while controlling the amount of foaming of the foaming material, control of the amount of foaming of the foaming material is halted, heating of the foaming material is removed and the foaming material is molded into a desired shape. The foaming material can be molded into a prescribed shape and at high speed even if the molded article is a complicated one.

Abstract: A radome structure has an outer first layer of a fiber-reinforced composite material of quartz fibers in a noncrystalline cured oligomeric cyanate ester pre-polymer. A second layer of a syntactic foam underlies and is bonded to the first layer. A third layer of the same fiber-reinforced composite material (although possibly of different thickness) underlies and is bonded to the second layer. A fourth layer of the syntactic foam underlies and is bonded to the third layer. A fifth layer of the same fiber-reinforced composite material (preferably of the same thickness as the first layer) underlies and is bonded to the fourth layer. The structure is formed by layup of the first layer inside a female mold, and successively shaping the remaining layers and tacking them to each preceding layer. The shell produced in this manner can be joined to conforming shells.

Abstract: Flexible graphite sheet is made by compressing a mixture of relatively large particles of intercalated, exfoliated, expanded natural graphite with smaller particles of intercalated, exfoliated expanded, expanded particles of natural graphite. The resulting sheet of flexible graphite exhibits increased electrical conductivity through the thickness ("c" direction) of the sheet and improved sealability perpendicular to the "c" direction.

Abstract: A method and apparatus (32) for making a three-dimensionally formed laminate (20) by positioning a mask (62) having an opening (64) above a flexible film (52) for rotation therewith such that a foamable liquid mixture (71) sprayed downwardly through the mask opening onto the film is distribute with the predetermined shape of the laminate to be formed. Separation of the mask (62) and the film (52) with the foamable liquid mixture (71) remaining on the film for processing during a transient state after substantial completion of expansion but before substantial curing. A flexible sheet (26) and the film (52) with the foam (71) therebetween are positioned between first and second three-dimensionally contoured mold surfaces (84,86) that are moved toward each other while the foam is in its transitory state to form the flexible sheet and provide a collapsed foam layer (28) that is bonded to the flexible sheet with the predetermined shape as the three-dimensionally formed laminate (20).

Abstract: An injection molding process for soles using expansible and cross-linking EVA based compounds. During the cooling stage of the molded sole, the spontaneous shrinkage of the molded sole is arrested by means of a template placed on the sole. To accomplish this, a series of perimeter pin elements extend from the bottom surface of the template and are coupled with a corresponding series of perimeter holes defined on the upper surface of the sole. The dimensions of the sole therefore will reduce no further either during the remaining cooling phase or after cooling.

Abstract: A process of forming and shaping a preheated workpiece made of honeycomb core material using a press including complementary male and female dies. The first step of the process is providing a carrier sheet for supporting the workpiece. The carrier sheet is suspended over the female die by two shafts supported by support towers. The next step is loading the preheated workpiece onto the carrier sheet. The next step is applying rotational torque to each of the two shafts whereby the carrier sheet is wrapped around the said shafts thereby applying tension to the carrier sheet and pulling the shafts toward each other and into pressing contact with the sides of the workpiece while said carrier sheet means supports the bottom surface of said workpiece.

Abstract: A composite material comprises a web shaped material which is impregnated with a curable resin and which contains thermoplastic particles distributed in the web shaped material. The thermoplastic particles are of an expandable type but occur in the composite material in substantially unexpanded form. The curable resin is in a A- or B-stage. In addition, the invention comprises use of a composite material of this nature for producing laminates by warm pressing and expanding the thermoplastic particles and a method for producing the composite material.

Abstract: On the surface of an ink-permeable sponge material having open cells, a melted portion and an unmelted portion are formed by a thermal head printer controlled by a memory processor for desired imprint data to prepare a stamp having the unmelted portion as an ink oozing imprint surface. Furthermore, a stamp material plate comprising the tape-like sponge material is wound up in the form of a roll and then received in a cassette case, and a stamp material cartridge comprising this cassette case is mounted in a cartridge receiving section of the thermal printer capable of printing in a tape form. A print image set by input from a keyboard or external input is printed on the stamp material comprising the sponge material fed from the cartridge by the thermal head, while the stamp material is pressed, to form a concave having a depth of 0.01 mm or more, thereby preparing a print plate for a stamp having a suitable length.

Abstract: A method of molding, from porous material, a low-density product having an impermeable surface. A mold is provided, which has a cavity, the outline of which defines the outline of the product. The starting material is a flat sheet of plastic foam. The first step of the process, in some cases, is a pre-heating procedure, which softens the material. Then, from this sheet there is stamped a blank having substantially the outline of the desired product, which is then inserted into the mold cavity. The mold is then heated with the blank therein to form the blank permanently into the desired product, after which the mold is quenched in cold water with the product still inside. The product is subsequently removed from the mold and frozen. The result of this molding method is a low-density product having an impermeable surface integral with the foam interior which is suitable for receiving various types of brightly colored finished.

Abstract: Open-cell plastic foam sheets with smooth, closed surfaces are heated up to a predetermined temperature after extrusion, are thermoformed in a thermoforming unit with the aid of a vacuum on both sides and are thermoset. One of the two closed surface skins of the plastic foam sheet is perforated with the aid of needles 4 arranged movably in a mold block 11. The mold block 11 is a component part of a thermoforming unit 10 and, together with a further mold block 9, forms the mold of this thermoforming unit. The mold block 11 for the inner side 13 of a plastic foam sheet 16 comprises a male mold 1, a cooling plate 2, a vacuum plate 3, the movable needles 4, a needle plate 5, springs 6 for the return of the needle. plate and also diaphragms 7 and a mounting plate 8, which are held together by screws 30.

Abstract: An elasticized geosynthetic panel, geofoam composition and method operable for permitting controlled deformation of earth materials adjacent a rigid earth retaining structure or the like. The panel includes a drainage component. a water and gas membrane and a compressible geofoam member. The compressible geofoam member is elasticized and exhibits a cross-anisotrophic characteristic which has enhanced elasticity in a direction normal to the geosynthetic panel.

Abstract: A footwear fitting system employs a set of sample footwear items, e.g., shoes, provided in small increments of length and width. The sample shoes are tried on by the wearer and the one providing the best fit is chosen. Then, a fit component of a stock shoe is re-formed with a molding apparatus to provide a size and width identical to the selected sample shoe. A shoe store need only stock a relatively small number of standard size shoes in order to provide the wearer with a close "custom" fit. The footwear interior is re-formed by mounting the footwear on a last having a length and width corresponding to that of the selected sample shoe. The last is heated to the softening temperature of a moldable strip of material, e.g., ethylene vinyl acetate (EVA), incorporated into the shoe upper, then allowed to cool, whereby the footwear interior shape and size is reformed to correspond to the last. In an alternative embodiment, the footwear item is a shoe insert, e.g., a shoe insole.

Abstract: An air-permeable plug member of a rubbery material useful as a stopper of the opening in a vessel, for example, for the culture of microorganisms and a method for the preparation thereof, by which the air permeability of the plug member can be freely controlled, are described. The plug member is characterized by the unique cellular structure consisting of a combination of a closed-cell structure and an open-cell structure in an appropriate proportion. Such a plug member can be prepared by first preparing a foamed rubber body consisting of a closed-cell structure only and then subjecting the same to a foam-breaking treatment by passing the body through a gap between, for example, a pair of rollers of which the gap width is 10 to 50% of the thickness or diameter of the body so that the cell walls of the closed-cell structure are partly broken to produce an open-cell structure.

Abstract: A method of prescoring foam board for making composite panels includes impressing a pattern of ridges projecting from a surface of a die into at least one face surface of the foam board. The pattern of ridges on the die forms a pattern of indentations having three series of parallel linear indentations, each series being angularly offset from each series other by 60.degree.. The ridges on the embossing die are pressed into the foam sufficiently deep that the the pattern of indentations impressed in the board surface after whatever springback occurs remain deep enough to enable volatiles generated in an interior zone of a panel to escape when drawn out by a vacuum pump when the foam board is heated under pressure between two face sheets of resin-preimpregnated fabric to form a composite panel.

Abstract: A floating board fabrication method including the steps of: (a) preparing a PE plate from foamed polyethylene by cutting, (b) grinding the PE plate to smooth the periphery, (c) instantly heating the PE plate thus obtained at about 180.degree. C. for about 4 minutes, (d) quickly cooling down the PE plate through a hydraulic cooling press at 4.degree. C., and (e) trimming the periphery of the PE plate thus obtained, polishing its surface, and coating its surface with a paint, so as to obtain a finished product.

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: The present invention provides a prooess for forming by extrusion a profile of extrudable material having a hard skin surface on a portion of the profile and a decorative enhancement on another portion of the profile. The decorative enhancement is formed integrally with the profile by use of an embossment technique on the profile before the extrusion material sets and hardens. The profile may be used in applications such as picture frames as well as door, wall and window moldings.

Abstract: A method and apparatus for densifying a thermoplastic polymer are disclosed. Particles of a thermoplastic polymer are introduced into a chamber, suspended with a fluid flow in the chamber, and while suspended, the particles are heated and softened to form pieces of densified thermoplastic polymer which are too dense to remain suspended in the fluid flow. The pieces of densified polymer are collected from the bottom of the chamber. A range of particle sizes can be efficiently and continuously densified without adjusting the apparatus.

Abstract: An artificial bait which can provide a great effect to attract fish by means of light emission or reflection from air bubbles contained in the artificial bait. A large number of air bubbles are enclosed within a artificial bait main body formed of elastic material having flexibility and light transmissible property wherein the air bubbles may be deformed to enhance the attractiveness of the bait.

Abstract: The cleaning elements are used in cleaning cassettes for cleaning the tape-contacting parts of a tape transport device, particularly a data tape transport device. The cleaning elements are high-density springy, absorbent foam pads each having an indented linear fused section or groove transverse to the direction in which wiping forces tend to remove the cleaning element from its holder. Ridges are provided in the holder to engage the grooves so as to securely hold the cleaning elements in place, and make it relatively easy to remove and replace them. The pads are made by partially die-cutting a foam sheet to form individual pads which can be torn free from the sheet along perforation lines, and forming the linear fused section in each of a plurality of pads simultaneously by contacting the sheet with a linear heated die.

Abstract: A method for manufacturing an integral multilayer foam board with concave/convex surface and multiple colors. The method includes steps of placing a multilayer foam body having multiple colors into a heating means to be heated and softened at a temperature within 130.degree. C. to 170.degree. C., placing the multilayer foam body onto a mold and pressed thereinto to be molded with multiple convex portions defined by concave frame lines, partially planing the convex portion of the foam body, and placing the planed foam body into the heating means to be re-heated at a temperature within 100.degree. C. to 140.degree. C., making the convex portions form concave portions and the frame lines become convex.

Abstract: A self-inflating structure consists essentially of a block of open-cell, resiliently compressible, foam material which has been shaped to a desired form and covered with an airtight envelope having a sealable aperture. The structure can be pressed to expel any air or other fluid out of the foam material and any internal void through the aperture. The structure is kept pressed or the aperture is sealed in order to keep it in its collapsed state. Upon release of the pressing form or the opening of the aperture, the block of foam bounces back to its original state sucking in ambient air and restoring the structure to its full size. The method for shaping the foam block includes extruding, machining, and carving with patterned sets of blades or burning wires.

Abstract: A reinforced foam core sandwich structure including opposing face sheets, a foam core therebetween, and tow members encapsulated within the foam core and extending between the opposing face sheets forming a support structure within the foam core between the face sheets.

Abstract: There is provided a process for manufacturing a heat-resistant molded foam product which comprises:(a) preheating a foamed polyester resin sheet of low crystallinity;(b) molding the sheet into a molded product,(i) heating only that portion of the preheated sheet which is convertible into a final product; such heating being conducted for a period of time such that the heated portion of the sheet reaches an average crystallinity of greater than about 20%, and(ii) cooling the unheated portion of said preheated sheet; and(c) cooling the resulting molded product,whereby distortion of the molded product is restrained when heated, and the molding time is shortened.

Abstract: A process for the manufacture of re-bonded foam products is disclosed. The process comprises mixing a liquid comprising polyol with a liquid comprising polyisocyanate in the presence of small pieces of foam, consolidating the mixture, and causing the polyol and polyisocyanate to react and bond the coated pieces together.

Abstract: The method of compression molding an article such as a closure wherein a thermoplastic resin is mixed with additives including a metallic pigment additive, extruded through a nozzle, cut by a blade into individual pellets, and each pellet is deposited into the cavity of a mold which is then closed to compression mold the pellet into an article, including the step of adding a blowing agent to the resin prior to extrusion in a quantity sufficient to randomize the metallic particles in the metallic pigment additive such that gaseous bubbles are provided in the extruded melt and that the gaseous bubbles are substantially expelled during the compression molding resulting in an article that is substantially free of blemishes which normally occur. Preferably, the method includes positioning a mixer plate in the path of the resin immediately prior to the nozzle.