Abstract: A method of producing dry processed fiberboards from resin-bonded waste composite wood products, wherein said wood products are chemically treated in a pre-heater unit of a refiner system under super-atmospheric pressure in the presence of steam to disrupt adhesive polymer bonds, formed into fibers in a subsequent disc refiner unit of the refiner system and further processed by a dry process to form fiberboards.

Abstract: A method of molding provides two molds (102, 104) formed of semiconductor material. The molds (102, 104) have substantially planar working faces (108, 110) into which recesses (106, 112) are formed. In use the molds (102, 104) are pressed together with the working faces (108, 110) opposed so the recesses (106, 112) form mold cavities. The molds (102, 104) only contact each other in the plane of the working faces (108, 110). A thermoplastic sheet placed between the molds is heated to deform the sheet into the mold cavities.

Abstract: A fibre mat as intermediate in the production of moulded pieces with preferably the same wall thickness is disclosed, comprising fibres made overwhelmingly of cellulose which are pressed together with a plastic in a homogeneous mixture. The plastic is in the form of fire with a length in the range of 30-100 mm and the cellulose fibres have a length of 10-100 mm. The cellulose fibres preferably comprise natural fibres, formed from, flax, sisal, hemp, kenaf, technical viscose fibres or mixtures thereof, or from regenerated cellulose, particularly synthetic cellulose obtained from wood.

Abstract: A recess of a thermoplastic resin container is formed by urging a part of a thermoplastic resin sheet into a cavity of a mold after heating the part of the thermoplastic resin sheet, so that a bottom portion and side walls of the recess are formed, wherein a bottom of the cavity has a convex shape area protruding in a depth direction away from the base portion formed on another part of the thermoplastic resin on the mold.

Abstract: A method for forming containers (C) comprises advancing a web material (2) along an advancing direction (F) to at least one operating stations (4, 5, 6, 7) in which at least one strip of containers (C) is formed from said web material (2), heating said web material (2) in said at least one operating station (4, 5, 6) by means of at least one heating element (41, 51, 61) and injecting a cooling gas through at least one space comprised between said web material (2) and said heating element (41, 51, 61); an apparatus for forming containers (C) comprises a feeding line for advancing a web material (2) along an advancing direction (F), at least an operating station (4, 5, 6, 7) arranged along said feeding line to form a strip of containers (C) from said web material, at least one heating element (41, 51, 61) for heating said web material (2) and injecting means (9) for injecting at least one cooling gas through at least one space comprised between said web material (2) and said at least one heating element (41, 51

Abstract: A process for producing an object made from plastic material with a mesh structure, wherein the mesh structure is deformed in at least one defined area, in such a manner that the original mesh structure of the area is eliminated and an essentially continuous structure and information can be introduced in this area.

Abstract: Blanks (12) of thermoplastic material are heated, and a thermoforming step is performed in which the heated blanks are deformed plastically by stretching. Before the thermoforming step, a die-punching step is performed in which the peripheral regions of the blanks are deformed by die-punching while the material of the blanks is held captive on the outside. The installation includes heater means (16) for heating said blanks, thermoforming means (24), and a die-punching tool (26, 28) suitable for deforming the peripheral regions of the blanks before they are thermoformed.

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

Abstract: A process for production of a monolithic article from a web of fibres of oriented polypropylene polymer, comprising the steps of subjecting the web to elevated temperature and pressure sufficient to melt a proportion of the polymer and compact it, and then cooling the compacted web, wherein an accelerated rate of cooling is employed down to 100° C. The process is of particular benefit when the weight average molecular weight (Mw) of the fibres is 250,000 or below. The resultant articles have good stiffness and strength, yet with reasonable ductility. Similar articles cooled slowly are brittle.

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: A thermoplastic composition comprising a polyimide resin, a polycarbonate resin, a polyimide-polysiloxane copolymer and talc.

Abstract: There is provided a method of producing a golf ball, capable of forming a cover to have a uniform thickness to produce a golf ball excellent in resistance to abrasion. The method includes a step to subject a cover material mainly composed of a thermoplastic resin to heat and compression molding to form a half shell, and a step to allow two such half shells to be arranged on a core or an intermediate layer, joined together, and heat and compression molded to mold the cover to have a thickness of 0.3 to 1.5 mm.

Abstract: An apparatus for forming sheet material (2), in particular sheet material based on natural fibers, comprises in sequence deformability promoting means (5) suitable for making said sheet material more easily deformable (2), forming means (9, 10, 11, 16a, 101a101b) suitable for deforming said sheet material (2); said deformability promoting means is deformability promoting material means (5). Forming means for shaping sheet material (2) comprises fluid forming means suitable for shaping portions of said sheet material (2), and a flow-inhibiting means (17, 116; 116a, 116b) suitable for preventing said fluid forming mean flowing through said sheet material (2).

Abstract: A process for forming an oriented orthopaedic implant prosthesis bearing, net-shape bearing, or near net-shape bearing includes the step of placing an irradiated UHMWPE preform or puck of a volume sufficient to accommodate the bearing in a compression mold and compression molding the irradiated preform. The molding is accomplished by applying heat and pressure to form the preform into a desired shape. The compression molding induces biaxial orientation in the formed bearing.

Abstract: A method of preventing delamination of multiple layers of an oriented polymer container having an opening defined by the multiple layers comprising a bi-axially oriented multilayer polymer container having an opening defined by a perimeter at which the multiple layers are exposed; heating the perimeter until workable; providing a curling die; feeding the multilayer perimeter into the curling die to curl the perimeter sufficiently to inhibit delamination of the layers and a container when so made.

Abstract: An apparatus for forming a bathtub liner over an existing bathtub comprising a container, a seal, a heating element, and a pressure increasing element. The container defines a cavity. The seal is associated with cavity and is capable of forming a substantially continuous seal with a bathtub liner. The heating element is capable of heating the cavity, and in turn, the liner. The pressure increasing element is capable of increasing the pressure within the cavity, to in turn, force a bathtub liner outwardly, away from the cavity. Upon positioning of the liner and apparatus over an existing bathtub the pressure increasing element will force the liner toward and into contact with the surfaces of the existing bathtub.

Abstract: A system (10) is provided for perforating and consolidating an uncured laminate sheet (14) at a substantially low pressure in one cycle of operation. The system (10) includes a pinmat (20) that is coupled to a tool base (24). This pinmat (20) is comprised of a mat portion (28) and a plurality of pins (26) extending from the mat portion (28). These pins (26) are intended to displace discontinuous fibers (32) within the laminate sheet (14) so as to perforate the laminate sheet (14). Furthermore, the mat portion (28) has one or more ventilation holes (58) integrally formed therein for allowing gas adjacent to the pins (26) to be withdrawn therefrom so as to improve the consolidation of the laminate sheet (14). The system (10) also includes a positive pressure source (12) that is coupled to the laminate sheet (14) for forcing the laminate sheet (14) onto the pinmat (20).

Abstract: Bottles, containers and other articles are formed from polypropylene compositions that include a reheating agent, such as antimony, carbon black, graphite, titanium, copper, manganese, iron, tungsten, graphite, infra-red absorbing dyes or other infra-red absorbing material. The reheating time for the polypropylene composition is shortened for injection stretch blow molding or thermoforming, and the polypropylene granule composition with reheating agent has an L* value of at least 80% of the L* value for a polypropylene granule control without added reheating agents as measured by the Gardner color test. The reheating agent may be incorporated into the polypropylene composition by in situ chemical reduction of a metal compound, such as antimony triglycolate, with a reducing agent, such as hypophosphorous acid. In addition, the polypropylene composition with reheating agent may be derived from a polypropylene masterbatch with high concentrations of reheating agent.

Abstract: An apparatus for repairing or refurbishing thermoplastic drums. A damaged drum, or at least a damaged portion thereof, is heated until it reaches a softened state and is then drawn over a template, or mold, having the substantially the same shape and size of an undamaged drum. The drum is allowed to cool sufficiently to return to its hardened state, whereby it substantially assumes the shape of the template. The refurbished drum is then removed from the template and is essentially ready to be used again.

Abstract: A radial force variation of a tire is corrected irrespectively of the kind of the organic fiber cord used, wherein a radial force variation (RFV) is measured at room temperature to specify a tire position indicating a minimum value of RFV, and an inner face of a tread portion is pushed and enlarged outward in a radial direction of the tire by a pushing means at a RFV bottom region sandwiching the position of the minimum RFV value from both sides thereof in a circumferential direction of the tread portion, and such a push enlarged state is kept for a given time.

Abstract: A handle for use in production of brushes by fusion. The handle is injection molded with a set of pre-formed holes. Each hole contains, on its bottom surface, a protrusion of excess material. Bristles for the brush are heated to form a small fuse at their ends. When the fused ends are inserted into the holes, material from the protrusion flows around the fuses, retaining them in the holes upon cooling.

Abstract: In one embodiment, the method far embossing a substrate, includes: heating a first substrate to a temperature above a glass transition temperature; preheating and maintaining a mold at a mold temperature below the glass transition temperature; introducing the heated substrate to the preheated mold; compressing the heated substrate in the mold; cooling the compressed substrate; and removing the cooled substrate from the mold. In another embodiment, the method for embossing a substrate, includes: heating a first substrate to a temperature above a substrate surface glass transition temperature; preheating a mold to a mold temperature of up to about 30° C. above the substrate surface glass transition temperature; introducing the heated substrate to the preheated mold; compressing the heated substrate in the mold; cooling the compressed substrate; and removing the cooled substrate from the mold.

Abstract: A polyolefin plaque is made by hot compaction of an assembly of fibres of the oriented polymer. It has been found to be beneficial to subject the fibres to a prior crosslinking process. Hot compaction is then less temperature-sensitive and produces plaques with excellent hot strength properties. Preferably the fibres have been subjected to prior stages of irradiation and annealing, both in a non-oxidising environment, for example acetylene.

Abstract: A lip rolling method for open-mouthed stacked thermoplastic containers. One particular method includes presenting a nested stack of containers having unrolled lips to a rim roller, engaging individual cups on a screw assembly, heating a supply of air in a heater to a desired temperature, discharging the supply of heated air toward the containers as they are engaged on the screw assembly, and rolling the lips of the containers in the screw assembly. The present invention may be designed to prevent the screw assembly from operating until the supply of air reaches the desired temperature. Additionally, the heater (e.g., a forced air heater) may be moved between an initial position proximate the nested stack of containers and a safety position in response to a signal. Such a signal may be generated in response to a temperature sensor, system error, or any other such triggering episode.

Abstract: A method and apparatus are provided for forming a sheet of polymeric material, such as polycarbonate. A forming mold is provided having halves that engage for forming a heated sheet therebetween. Each of the halves defines an interior cavity having a peripheral edge. The sheet is retained between the peripheral edges of the halves and a vacuum is generated within one of the cavities for drawing the sheet therein, whereby a sensing mechanism detects a draw depth for initiating a cooling mechanism to cool the sheet to a temperature below a glass transition temperature of the material. A series of retention mechanisms are provided about the peripheral edge of one of the halves, for biasing the sheet into engagement with the peripheral edge of the opposing half. A trimming mechanism is further provided for trimming the perimeter of the sheet to a desired form.

Abstract: A sunshade production method and system for producing a sunshade for use with a sunroof of a vehicle with high efficiency and low cost. The production method includes the steps of: cutting one side of a thermoplastic resin plate to create a base member of the sunshade; heating the base member to a predetermined temperature; overlapping a bottom surface of the heated base member with a surface material in a manner that one end portion of the surface material is extended from an end surface of the base member, pressure-forming the base member and the surface material overlapped with one another at the same time; wrapping the extended end portion of the surface material around the end surface of the base member; and removing unwanted portions of the base member and the surface material to finalize the sunshade.

Abstract: A stretch-blow-molded container obtained by biaxially stretching and blow-molding a thermoplastic polyester and which exhibits heat resistance or heat resistance and pressure resistance to withstand sterilization by heating at the time of hot filling. The stretch-blow-molded container is obtained by stretch-blow-molding a preform formed of a thermoplastic polyester as a chief component, wherein the body portion, bottom portion and shoulder portion are stretch-oriented, and at least the central portion in the bottom has an endothermic peak (B) due to the extinction of pseudo crystals in a temperature region higher than a glass transition point of the polyester but lower than a temperature at which the crystals of the polyester start melting as measured by using a differential scanning calorimeter (DSC).

Abstract: Methods for forming data storage media and the media formed thereby are disclosed herein. In one embodiment, the method for forming a data storage media, comprises: injection molding a substrate comprising surface features, wherein said surface features have greater than about 90% of a surface feature replication of an original master; and disposing a data layer over at least one surface of said substrate; wherein said data storage media has an axial displacement peak of less than about 500&mgr; under shock or vibration excitation.

Abstract: An apparatus for heating a pin shaped thermoplastic material is provided including a quartz tube, a heat radiator and a securing mechanism. The quartz tube has tube ends and is helix shaped. The heat radiator is arranged in the quartz tube and includes an electrical resistance wire connected to a power supply. The securing mechanism is a heat resistant element connected to the quartz tube that secures the part to be heated relative to the quartz tube along an axis of the quartz tube and heats the plastic part. The quartz tube and/or the part to be heated are moveable. An apparatus is also provided for heating a number of pin shaped plastic parts simultaneously. In addition, a method for heating one or more pin shaped plastic parts is also provided.

Abstract: An improved pressware die set includes mechanical ejectors for removing formed product from the punch. A preferred embodiment includes rocker-style ejectors free from edges or other asperities which may tend to snag and mar the product during the production process. Most preferably, the outward surfaces of the rocker members extend beyond the perimeter of a paperboard blank positioned for forming so the paperboard blank does not encounter an obstruent outward edge during forming.

Abstract: In the step of cladding by applying a pressing force to a ceramic stack body, while a frame being punched into a stack body and kept therein, the stack body is pressed by a pressing force applying member located inside of the frame. According to this method, no deformations are created in the direction parallel to the surface of the stack. Therefore, such a problem as the deformation of a conductive layer due to stress in not caused, resulting in a stack body with an excellent densified structure and, when resulting stack bodies are sintered, ceramic electronic components formed of them are free of defective connections, structural defects and electrical performance failures with an excellent yield rate. In addition, by heating a stack body at applying a pressing force thereto, the densified stack body is formed under a reduced pressure. Furthermore, by having an elastic body provided to the pressing force applying member, a stack body is pressed uniformly.

Abstract: A method of making a coated, molded cellulosic fiber board, including the steps of: applying a primer composition comprising a polymer to a surface of an already-compressed cellulosic fiber board, the composition formulated to form a chemically crosslinked polymer matrix when applied to the board; treating the board with steam; heating the board to its thermal softening point, wherein the wood fiber material of the board is plastically deformable; and pressing the treated, primed board into a desired shape, is disclosed.

Abstract: A drumhead mold and process for making a plastic drumhead. The mold is structured to heat the drumhead collar area and maintain the battering surface cool to provide a drumhead with improved performance characteristics.

Abstract: The invention relates to a process for shaping plate-shaped thermoplastic material into three-dimensional molded bodies with the process steps: insertion of the heated plastic plate to be shaped into a concave mold part, sealing the mold part at its upper edge by covering with a membrane made of a material impermeable to gas and elastically stretchable, pressing the membrane onto the mold edge by means of a rigid covering, and supplying compressed gas to the space between the membrane and the covering, along with an arrangement for carrying out the process.

Abstract: There are provided apparatuses and related methods for forming sheets. The formed sheets can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic, which can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. The apparatus includes a heater for heating the sheet to a processing temperature and a structure for configuring the sheet to a desired shape using one or more rollers, shapers, longitudinal members, and/or support members.

Abstract: An apparatus and method are provided for thermoplastically forming a contour in a thermoplastic duct defining a passage. The apparatus includes a longitudinal collar that defines a cavity and a rigid inner support structure extending longitudinally in the cavity. The collar and/or the inner support structure define a mold contour. One or more heaters are configured to heat at least a formation portion of the duct to a formation temperature. An expansion member, such as an expandable elastomer, which is disposed between an inner surface of the collar and an outer surface of the inner support structure, is configured to urge the formation portion of the duct against the mold contour to thermoplastically form the duct.

Abstract: A method of manufacturing a door skin includes the steps of providing a wood composite flat blank. The blank is placed between the platens of a heated press, the platens being heated to a temperature sufficient to soften the resins in the blank and to thereby soften the blank. Sufficient pressure is applied to close the platens and thereafter the pressure is cyclically applied to increased pressure levels for thereby causing the blank to be deformed into a molded shape determined by the configuration of the platens. The molded blank is then removed from between the platens.

Abstract: A method and apparatus for repairing or refurbishing thermoplastic drums, by which a damaged drum, or at least a damaged portion thereof, is heated until it reaches a softened state and is then drawn over a template, or mold, having the substantially the same shape and size of an undamaged drum. The drum is allowed to cool sufficiently to return to its hardened state, whereby it substantially assumes the shape of the template. The refurbished drum is then removed from the template and is essentially ready to be used again.

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

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

Abstract: An improved pipe belling process is shown which features a mandrel having a specially designed backup or forming collar. The backup collar has an exposed lip portion which forms a complimentary angle with the outer sloped surface of the gasket which it abuts. The complimentary angles of the backup collar and gasket form a wedge shaped contact area which serves to retain the gasket in its initial circumferential position on the working surface of the mandrel as the heated pipe is forced over the mandrel and gasket.

Abstract: Method and apparatus for manufacturing of pre-inkable rubber stamps from micro porous thermo-plastic material (6) by use of thermal head (1), where material is compressed by not less than 0.5 mm and the controller switches on and off the heating elements (2) of the thermal head (1) in accordance with a pattern received from the computer, creating by melting the surface of the said material ink non-permeable elements, characterized in that the surface with the heating elements of the said thermal head has appropriate configuration that the stretching out of melted surface layer (5) of the said material under the elastic tension of the material (6) releasing from the compression by the thermal head (1) is avoided.

Abstract: A press apparatus includes a movable member having a mold-mounting surface for mounting a movable mold thereon and at least four guide surfaces; and a guide member having at least four guide surfaces facing the corresponding guide surfaces of the movable member. Fluid is injected into a space formed between the guide surfaces of the movable member and the corresponding guide surfaces of the guide member such that the mutually facing guide surfaces are held in a noncontacting condition.

Abstract: A core for winding a continuous web of material. In one embodiment of the present invention, the core includes a first inner portion and a second outer portion. The inner and outer portions once had the same inner diameters. However, the outer portion is resized to having a second inner diameter so that it may overlap the first inner portion. A workpiece, which will be cut into a plurality of second outer portions, is heated. The heated workpiece is then placed over a plug which has an outer diameter that substantially corresponds to the desired inner diameter for the second outer portions. By placing the heated workpiece over the plug, the workpiece is stretched to have the desired second inner diameter. The workpiece is then cut into a plurality of second outer portions of the desired width. Because the inner diameter of each second portion is now larger, they are permitted to overlap a corresponding first inner portion.

Abstract: A method of manufacturing a rear shelf trim and speaker grill panel (12) for an automotive vehicle (10) includes steps of punching a substrate layer (16) of a polypropylene and flax material with a punch set (46) to form a grill section (60) and placing a decorative carpet layer (18) over the substrate layer (16) and molding the two layers into a combined speaker grill and rear shelf trim panel (12).

Abstract: Method for decorating the top of a compression-molded cap of synthetic material intended to close a container, in which the decoration is positioned on a flat support in the form of a disc which is placed in the cavity of the cap forming mold before the constituent material of the cap is introduced, and is found to be bonded to the top of the cap after its removal from the mold.

Abstract: A device for restoring a necked-down end of a plastic core includes molding and curing stations and a core handling system having a carriage for sequentially positioning the core adjacent the stations. The molding stations are heated and cooled, respectively, by heating elements and a chilled coolant. A core handling system includes a core-supporting carriage slidably supported on first rails for engagement between the core and the stations. The first rails are slidably supported on perpendicularly oriented second rails to provide for sequential alignment of the carriage with the molding and curing stations. A control system includes motor drives controlled by a programmable logic controller having a processor. Sensors communicate signals to the processor representing the position of the carriage with respect to the upper rails and the position of the upper rails with respect to the lower rails for actuation and control of the motor drives.

Abstract: A method for manufacturing a wear-resistant three-dimensional foamable structure includes the steps of: a) preparing a retractable heat deformable wear-resistant substrate; b) working the substrate by a forming mold to form a housing having a three-dimensional shape, the housing having an inside formed with a receiving space; c) placing or directly forming a foamable body in the receiving space of the housing, so that the foamable body is combined with the substrate integrally, so that the wear-resistant substrate is mounted on an outer layer of the foamable body, thereby protecting the foamable body and enhancing an outer appearance of the foamable body; and d) cutting and trimming an edge of the substrate or the foamable body, thereby forming a foamable product.

Abstract: A molding method and an impact resistant automotive part such as a bumper beam resulting from the molding method are obtained wherein a thermoplastic reinforced fiber structure at least partially forms a pair of attachment portions of the part and continuously extends between the attachment portions to link the attachment portions. The method includes the steps of providing a plurality of blanks, heating the plurality of blanks, and stacking the plurality of blanks to form a stack of blanks. The stack is then stamped to form the part including the pair of attachment portions spaced a predetermined distance apart. The thermoplastic reinforced fiber structure has tows of fibers wetted by a resin material such as polypropylene. Preferably, the fibers are woven glass fibers.

Abstract: The present invention provides a door panel having a decorative insert integrally attached to the door panel. In one embodiment, the method of forming the door panel comprises forming the decorative insert by preheating a substrate and placing a coverskin on top of the substrate. The substrate and the, coverskin are subject to a compression molding process to form the decorative insert. The decorative insert is then disposed inside a second molding tool and a plastic material is injected into the cavity of the second molding tool. The plastic material then forms the door panel.