Abstract: A method for constructing a plastic door for a household electrical appliance such as a refrigerator having an outer door shell to which is assembled an inner door liner. The outer shell is formed into a concave dished shape having a continuous side wall. Following forming, the edge of the shell side wall is heated and bent to form a flange extending toward the inner cavity of the shell. Heating and bending of the edge is implemented while maintaining the shell in a mould and acting on the free edge of the side wall. A door outer shell made by this method includes a side wall with the edge of the side wall bent towards the interior of the shell, and when a door liner is secured to the outer shell, the bent continuous edge of the side wall is exposed to view and has an attractive appearance.

Abstract: The present invention provides a manufacturing method of a compressible printing layer, comprising a vulcanizing step comprising a first heating process in which one surface of a compressible printing layer including an unvulcanized compressible layer containing microcapsules is heated by bringing the one surface of the compressible printing layer into contact with the surface of at least one heated metal roll while applying tension to the compressible printing layer, and a second heating process in which the other surface of the compressible printing layer is heated by bringing the other surface of the compressible printing layer into contact with the surface of at least one heated metal roll while applying tension to the compressible printing layer.

Abstract: A method for forming a plastic prosthesis bearing, net-shape bearing or near net-shape bearing is provided. The method includes providing a cross-linked plastic resin preform in a volume sufficient to accommodate the bearing and molding the cross-linked preform. The molding is accomplished by applying heat and pressure to form the preform into a desired solid plastic shape. The heating and pressure is sufficient to melt the plastic resin so that the plastic resin flows under pressure and quench remaining free-radicals.

Abstract: A composition and method for forming plant containers, such as plant propagation trays providing control of plant root growth. The method includes applying to a sheet of thermoformable plastic an aqueous coating composition including between approximately 20% and 45% by weight non-delaminating acrylic latex, between approximately 8% and 30% by weight copper hydroxide, between approximately 2% and 20% by weight filler, and between approximately 0.5% and 5% by weight dispersant. The coating is dried and the plastic sheet is heated to a temperature sufficient to form the plastic. The plastic sheet is then formed into a desired shape.

Abstract: Formed composite structural members and methods and apparatus for making the same are described. The composite members are formed by using a continuous roll pressing process or apparatus, or a consolidated cold press process. Using these processes, the composite members are formed with a better surface finish using shorter cycle times and without spreading of the tows.

Abstract: A print pad for printing on hard surfaces is made by first forming a mold having a textured surface, then forming the print pad in the mold. The textured surface of the mold is made by first manufacturing a sheet of plastic the surface of which has the desired texture, then using a thermoforming process to shape the plastic into the mold.

Abstract: The present invention provides a sound insulating structure cover panel that compliments the sound attenuation material. The method of manufacturing the panel includes the steps of providing a laminated blank having an interior face which will be observable from the passenger compartment. The side opposite the interior face of the blank has a generally non-permeable polymeric layer adjacent to a primary backing and a secondary backing layer overlying the polymeric layer. In the preferred process, the previously described blank is elevated to a desired temperature and positioned in a closed forming mold such that the perimeter of the blank is retained in a fixed position. The forming mold is closed with a controlled pressure that is sufficient to expand the blank, conform it to the mold and render a panel having a desired permeability.

Abstract: A process and apparatus utilize an extrusion and zone molding process in which a polymeric material is extruded, shaped and cooled to form a primary extrusion having a shaped length of uniform cross section, zone heating is then applied to only a portion of the primary extrusion creating a molten zone in that portion, the molten zone is aligned with a section mold to mold only that portion of the primary extrusion. The portion section molded cools quickly forming a section molded portion. Although an examplary polymeric component is described herein, a variety of components may be produced utilizing the apparatus and method described by varying the shape of either the primary extrusion component or the section molded component, or both.

Abstract: A method and apparatus for molding thermoformable sheet material is set forth. The method includes the steps of providing a conventional stamp type mold, one section of which provides a compliant mold member which is augmented by diaphragm. The diaphragm coacts with the compliant member during a molding phase to ensure dimensional uniformity in the molded article. Further, tight or detailed areas are easily molded by making use of the compliant and diaphragm members. In a further embodiment, tension adjusting is achieved during molding by a series of discrete tension members. The tension members cooperate with the compliant and diaphragm members to significantly improve dimensional uniformity and prevent wrinkling in the molded article.

Abstract: An improved, economical, high speed method for attaching a fibrous material to a plastic substrate involves positioning a fibrous material over a surface of a plastic substrate, directing a stream of heated air through the fibrous material and at the surface of the plastic substrate to melt the surface of the plastic substrate, compressing the fibrous material against the melted surface of the plastic substrate, and allowing the melted surface of the plastic substrate to cool and resolidify, whereby fibers of the fibrous material become embedded in the resolidified plastic.

Abstract: A thermoplastic conformal tool/vacuum bag that is structured to substantially conform to a surface or a cavity in a composite structure is placed proximate to a uncured composite member to fabricate a composite structure. External heat and external pressure are applied to cure the member. The conformal thermoplastic tool/vacuum bag is removed from the cured assembly by reheating, if necessary, to facilitate removal of the tool/vacuum bag.

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: A thin-walled polymeric component that may have a selected complex shape, and a method of forming the component. The method includes heating a portion of a polymeric film to a selected malleable temperature, and forming a protrusion in the heated portion while it is malleable. The protrusion defines a protrusion having a first shape. The method also includes positioning a forming tool in the protrusion's interior and drawing a partial vacuum from within the protrusion so as to exert a force on the protrusion and move the protrusion's sidewalls inwardly into engagement with the forming tool. As the partial vacuum is drawn, the protrusion moves to a second shape that may be different than the first shape and that closely conforms to the selected shape of the forming tool. The protrusion is cooled below the malleable temperature and the forming tool is then removed.

Abstract: Mechanically embossed resilient surface coverings having superior textural fidelity are prepared by mechanically embossing a polyurethane coated floorcovering before the polyurethane is cured. The mechanical embossing is conducted when the polyurethane is dry and the underlying plastic layer and the polyurethane are softened by heating. After the mechanical embossing step, the polyurethane is cured using ultraviolet (UV) light. The product can be cooled before or after UV curing. The invention is applicable to a variety of resilient surface covering products including floor and wall coverings which otherwise have a wearlayer which can be softened by heating. This includes surface coverings having the full range of decorative effects available in the art, including surface coverings which also have been, for example, chemically embossed, mechanically embossed, chemically and mechanically embossed or not embossed at all prior to application of the process of the invention.

Abstract: The invention is a method of forming an array of caps for attachment to a wafer which includes a plurality of microfabricated devices. The method includes sandwiching a sheet (134) of thermoplastic material between upper and lower molds (102, 104), heating the sheet to a plastic state and molding the sheet into caps. The molds (102, 104) are preferably formed of silicon and infrared radiation is preferably used to heat the sheet (134).

Abstract: A molding composition including reactive high-volatility monomeric groups, such as acrylics, at least one primary thermal initiator and at least one secondary thermal initiator is described. Molding process using molding compositions including reactive high-volatility monomeric groups are also described.

Abstract: A device and method for forming tableware from biodegradable vegetable fibers includes a device for punching a sheet of vegetable fibers into a preset shape and forming final products from the vegetable fibers. The device and method include a humidifier for humidifying the vegetable fibers, a bender for bend-drawing the vegetable fiber into an intermediate article, a warm-air dryer for keeping and drying the intermediate article, a cool-air dryer for further drying and cooling the intermediate article into a finished article.

Abstract: A container with an integrally molded flap for covering an opening has a top that is deflected during cooling to provide a self-closing capability. This capability is provided by causing the top to cool to room temperature when the flaps are closed into a warped shape, either concave or convex in which the hinge formed integral with the flap and the rest of the cover is curved with the flaps closed. This could be done by careful design of the cap such that it warps this way during cooling naturally, or by pressing on the cap during cooling to “set” the cap and hinge in a curved shape. When the flap is opened, the arrangement of the flap and hinge reduce the chance that the flap will return to its as-molded position and jam.

Abstract: Processes for producing durable three-dimensional bowls such as water basins comprising plastics preferably acrylics heavily filled with alumina trihydrate, some embodiments including visible particles such as those sometimes used for simulating nature stone. A preferred process for manufacturing the bowls of such material includes defining a flat rigid blank such as from a larger rectangular bulk sheet in the approximate top outline shape of bowl to be formed, e.g., the blank being oval for an oval bowl and circular for a circular bowl. The blank is provided a smooth side which will be the concave finished and exposed side in use. The blank is heated to a point of softening and of uniform temperature throughout, located within a molding die such as a matched molding die having a female cavity of the desired bowl shape, indexed to the die, but left generally unrestrained so that the heated blank and un-clamped edges thereof are allowed to draw inward to reduce tension loads during forming.

Abstract: Si material, which has been considered to be very brittle, and hard to bend, is heated to at least its brittle-ductile transition temperature. A bending moment is applied to a heated portion of the Si material so that a slip deformation is generated. Whereby it is possible to perform bending, and to greatly improve a degree of freedom for machining the Si material. The Si material has a brittle-ductile transition temperature which transfers from a brittle to a ductile state at its brittle-ductile transition temperature. At the transition temperature or more, the Si material is in a state that a slip can to be generated between its crystals in response to a bending torque applied thereto. Thus, when a bending moment is applied to the heated portion of the Si material which is heated to the transition temperature or more, a slip is generated between lattices or between crystal grains in the heated portion, so that the Si material is deformed.

Abstract: A method for shaping an object. The method includes the steps of preparing an attachment material having a glass transition temperature lower than that of the object, fixing the attachment material on the object, forming the object into a predetermined shape, heating the attachment material until the temperature is higher than its glass transition temperature, and cooling the attachment material and the object until the temperature is lower than the glass transition temperature of the attachment material. Additionally, shaping of the object and heating of the attachment material can achieve the same results.

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: Polytetrafluoroethylene thin film comprising a thin film of polytetrafluoroethylene having thickness of ≦20 &mgr;m; surface roughness (Ra) of ≦0.1 &mgr;m; tensile strength of ≧80 N/mm2; and light beam transmittance of ≧80% for light of 500 nm wavelength. A process for manufacture of polytetrafluoroethylene film comprising compressing porous polytetrafluoroethylene film at a temperature above the melting point of the film, followed by cooling to a temperature below the melting point of the film while continuing to apply pressure.

Abstract: A method of forming a socket on a pipe of thermoplastic material is disclosed. In the process, an end section of the pipe is heated in a heating station. Then, the pipe is transferred to a socket-forming station having a socket-forming mandrel. This is followed by the socket-forming mandrel being introduced into the pipe end section, heated to a suitable socket-forming temperature, and the end section being formed into a socket. Prior to the pipe end section being heated in the heating station, a support is introduced into the end section in order to internally support the end section. The support remains in the end section after the socket-forming mandrel is introduced into the pipe and in the process the support is pushed deeper into the pipe.

Abstract: An extended component made of fibre-reinforced thermoplastic materials, in particular a screw (1) that contains a corresponding proportion of fibres. Carbon fibres shaped as endles fibres extend in an at least approximately parallel direction to the centre line of the screw (1) in the area of the head (2) of the adjacent thread turns of the shaft (5). At the surface of the remaining part of the threaded portion, the fibre follow the contour of the thread in the axial direction of the part. The fibres in the core of this section next to the end of the screw are distrubuted in an increasingly random manner towards the free end of the screw.

Abstract: A matrix is formed into a desired shape by pouring transparent liquid material into a mold. The material progressed from the liquid to the gelatinous state. Laser sculpting steps are performed when the material is still in a gelatinous condition to form small spots in the matrix. Because the material is non-solid gel when the laser beam applies its focused energy, there is no cracking or destruction. Intensity and duration of the laser pulse determine the size of the spots as does the timing in relation to the matrix material finally changing from gel to solid. Particular visual effects are produced at different degrees of solidity when sculpting. The liquid in the mold may be pressurized for removal of air bubbles after initial pouring of the matrix material and application of pressure after the laser sculpting controls the size of the spots in the finished product.

Abstract: A green ceramic core or other article at elevated temperature is placed between a complaint member and a relatively rigid setter while the green core or article cools to a lower temperature. The compliant member can comprise a fluid pressurized compliant bladder or a compliant, non-rigid setter or facing layer thereon for contacting a side of the green core or article.

Abstract: A forming track forms flexible plastic tubing which carries fuel from a fuel tank to an engine into a desired shape. The forming track includes a curved channel to receive a round tubing and a pair of opposing flanges to secure the tubing in the forming track. The tubing slightly deforms between the pair of opposing flanges as the plastic tubing is positioned in the channel. After the tubing is inserted, the opposing flanges secure the tubing in the forming track. While positioned in the forming track, the tubing is set by heating and rapid cooling, thermosetting the tube into the shape of the forming track.

Abstract: A method and apparatus for forming a skid-resistant surface on a thermoformed object such as a bed liner. The method includes forming a blank of extruded plastic material, abrading the surface with a wire brush, reheating the blank and thermoforming the blank to open the abraded surface of the blank. The apparatus includes an extruder delivery mechanism delivering a blank of sheet material to a wire brush which is turned by an electric motor at a speed slightly greater and in the same direction as the travel of the blank under the roller.

Abstract: This invention is a compression molded part useful for transportation vehicles and in construction and a process for making compression molded parts. These light weight parts are molded at pressures less than 500 psi (3.5 MPa) and are made from a sheet molding composition or bulk molding composition which incorporates a thixotrope such as fumed silica.

Abstract: An embedding hole is formed in a base made of thermoplastic resin, an embedded part is inserted in the embedding hole, the base is subjected to heating treatment for softening the base to bring the base into an elastomeric region and restraining treatment for restricting outward thermal expansion of the base to thereby expand the base in an inward direction of the embedding hole 2a to reduce a hole diameter and to deform a hole wall of the embedding hole along a shape of an outer wall face of the embedded part and to bring the hole wall into close contact with the outer wall face, and then the base is cooled and hardened.

Abstract: A method for manufacturing a zipper without shift in injection molding comprises the steps of forming a bank of continuous zipper teeth at an edge a zipper strip; scraping a part of zipper teeth on the zipper strip; melting two layers of films and coating the films on the upper and lower sides of the zipper strip; punching holes at an inner lateral sides of the films; guiding two zipper strips into an upper and a lower engaging piece molds; and expanding the zipper strips; injection-molding engaging pieces; moving the molds from the zipper strips; cutting the zipper strips along the holes, thus forming the upper and lower engaging pieces of a zipper. When forming the hole, a connecting strip at an edge having the films must be retained. Thereby, the zipper strips can be precisely positioned in the upper engaging piece mold and the lower engaging piece mold.

Abstract: A manufacturing method for a filter element having a filter portion and a flange portion formed along an outer periphery of the filter portion to protrude outwardly. First, a corrugated intermediate product having plural ridges of the filter element is formed by folding. Next, the flange portion is formed integrally with the filter portion by pressing an outer peripheral portion of the intermediate product at a high temperature. While the flange portion is formed, each of sides of the intermediate product extending in parallel with the ridges is restricted to a position corresponding to a shape of the filter element by plural forming jigs. Therefore, sides of the flange portion extending in parallel with the ridges are formed simultaneously when the flange portion is formed and do not need to be trimmed after forming. As a result, a material of the filter element is less wasted.

Abstract: A fabrication and adhesion method for a polyaryl-ether-ketone (PAEK) device, such as a microfluidic device, is disclosed. At least one glassy uncrystallized PAEK substrate is heated up to near or above the glass transition temperature to allow the substrate to crystallize from the glass state, while embossing the substrate with patterns. Bonding the PAEK substrate to another substrate is accomplished using a solvent-resistant adhesive, such as a polyimide-based adhesive, in combination with an adhesion enhancement treatment. In certain embodiments, the adhesion enhancement treatment is a plasma treatment or a chemical sulfonation treatment.

Abstract: A gas sensor includes a sensor element for determining at least one physical quantity of a gas, e.g., for determining the concentration of a gas component in an exhaust gas of an internal combustion engine or the temperature of the exhaust gas. The sensor element is fixed in position by the sealing system in a housing of the gas sensor. The sealing system includes at least one sealing element, which includes a mixture of a ceramic material and a glass. The hemisphere temperature of the glass is above 750° Celsius.

Abstract: Method and apparatus of forming articles includes a press having a pair of opposite platens. An articulated clamping frame is mounted between the platens, each of which are moveable toward and away from the clamping frame. Material to be formed is clamped into the clamping frames and the articulated clamping frame is wrapped around the die as the die forms the material. The formed article is extracted from the die by moving the clamping frame away from the die.

Abstract: This invention relates to a splittable medical device incorporating two sets of preferential tear lines. The first set of preferential tear lines preferably includes two longitudinally extending skives formed along the exterior surface of the proximal portion of the splittable medical device. The second set of preferential tear lines preferably includes a plurality of grooves formed along a distal portion of the interior portion of the splittable medical device. The skives should be substantially aligned with some of the grooves. This configuration facilitates splitting of the medical device along the skives and along one or more of the grooves to allow a clinician to split the medical device completely into two pieces. This invention includes a special mandrel having a plurality of ribs formed along a distal portion thereof and process that is used to manufacture the splittable medical device.

Abstract: A film and heated plastic blank are sized to fit over a mold cavity and a combination of said film and blank formed. The combination is positioned over the mold cavity and formed in said mold cavity into the shape of said mold cavity.

Abstract: Disclosed is a method of producing a shaped article suitable for use as the load bearing component of a prosthetic device formed from ultrahigh molecular weight polyethylene. polyethylene.

Abstract: The invention relates to a method and device with which it is possible to arrange complicated shapes with considerable differences in height in wood fiber board, and in particular but not exclusively so called MDF (Medium Density Fiberboard). The deformation of the wood fiber board which can be achieved with the invention is known in the art as extusion, wherein a considerable plastic deformation takes place accompanied by flow and stretch of the material.

Abstract: The invention is concerned with an integrated process for the manufacture of polymer and/or composite products, comprising the integration of processing operations to achieve a plurality of material conversion steps, such as impregnation, consolidation and bonding, within one single controlled fabrication cycle. The process includes an in-situ final preparation of at least one composite preform at the location of the moulding operation and an integrated moulding operation comprising a step of providing an additional matrix-functioning material into the mould to at least partially enclose the composite preform, the operation of providing the additional matrix-functioning material providing the pressure for an in-situ final consolidation of the composite product.

Abstract: A method of making a part made of a reinforced plastics material in a mold including at least two portions and from a reinforced sheet or from a lay-up of reinforced sheets including at least one reinforced sheet, in which method the reinforced sheet (4) is pre-heated. The reinforced sheet or the lay-up of reinforced sheets is presented to a first portion (1) of the open mold by a picking-up device including pressers (6a; 6b; 7), at least a region of the reinforced sheet or of the lay-up is applied against a corresponding region of the first mold portion by pressers on the picking-up device, the remainder of its surface is applied against the first mold portion while holding stationary the region of the reinforced sheet or of the lay-up, the mold is closed, and the resulting part is removed from the mold.

Abstract: An orthopedic implant is formed from a sheet of moldable material such as a polymer or a bioresorbable material using an instrument. The material is heated above its glass transition temperature so that it can be formed into the desired shape of the implant. Then the material is cooled below its glass transition temperature to harden the material such that it retains the implant shape. During surgery, a surgeon can form implants to fit unique orthopedic applications by using instruments having various internal and external mold forms between which the sheet of moldable material can be rolled, wound, pressed or drawn.

Abstract: The invention relates to a method and device with which it is possible to arrange complicated shapes with considerable differences in height in wood fibre board, and in particular but not exclusively so-called MDF (Medium Density Fibreboard). The deformation of the wood fibre board which can be achieved with the invention is known in the art as extrusion, wherein a considerable plastic deformation takes place accompanied by flow and stretch of the material.

Abstract: An improved process for producing a consolidated polymeric monolith from an assembly of thermoplastic polymer. The assembly is placed under pressure to fill a majority of the voids thereof by mechanical deformation of the fibers, and heated to a temperature too low to melt the fibers at the deformation pressure but sufficiently high to at least partly melt the fibers at a lower transition pressure. While maintaining the assembly at this temperature, the pressure is reduced to the transition pressure long enough for partial melting of the fibers to fill the rest of the voids, and then is increased to a consolidation pressure at least as high as the deformation pressure. The assembly is cooled slowly to ambient temperature at the consolidation pressure. The process allows accurate control of thermal expansion coefficients of the product. Further, products of manufacture produced by the process exhibit improved strength, thermal stability, infrared transparency and unique intrinsic physical characteristics.

Abstract: The texturing, patterning and bending of a solid surface material. The end product can be achieved both through casting technologies and heat pressure processes. Controlled surface deformation can be created in a pre-manufactured flat sheet and the sheet can then be heated and bent using conventional thermoforming technology. This contrasts considerably with the conventional norm, whereby an embossed solid surface sheet, when reheated, loses its embossing.

Abstract: There is herein disclosed a multi-layer structure which can suitably be used to manufacture a container in which sealing properties are improved for the prevention of container breakage during sterilization by heating, cooking by heating, distribution or the like and heat resistance is improved for the prevention of container deterioration and which is excellent in opening properties; and a container having the above-mentioned excellent characteristics which comprises this multi-layer structure.

Abstract: The vacuum insulator in accordance with the present invention comprises glass white wool body which density is 0.1˜0.5 g/cm3 in density and is below 0.0023 kcal/mh° C. in thermal conductivity, and a non permeable container surrounding the body in which the pressure is between 10−6 ˜10−1 torr. The vacuum insulator is fabricated by piling up glass white wool, thermal-pressutizing the piled glass white wool to form a body of 0.1˜0.5 g/cm3 in density wherein the pressurizing is done at 0.007˜1.5 kg/cm2 and under 20° C. for more than 10 minutes, putting the body in the non-permeable container, and producing a vacuum in the container.

Abstract: A machine and method for providing a folded liner for insertion into a pipe, comprises an upper section and a lower section. A flattened heated thermoplastic liner is fed downwardly through the upper section to the lower section, where it is redirected and fed substantially horizontally from the lower section. The flattened liner introduced to the upper section is broadly indented at one side of the liner and is then more acutely indented to provide loops disposed side-by-side in a substantially horizontal direction. The lower section reorients the loops so that they are stacked side-by-side in a substantially vertical direction. The liner is cooled as its leaves the lower section to maintain its cross-sectional configuration. The upper section is separable from the lower section, and portions of the upper and lower sections are displaceable and removable to facilitate insertion of the liner into the machine and removal of the machine from the liner.

Abstract: The present invention is directed to a golf ball comprising a solid core component that includes a relatively hard central portion and a relatively soft skin portion surrounding the central portion. Various preferred embodiment golf balls are disclosed utilizing this core configuration. A golf ball comprising the noted core component having a wound layer disposed about the core skin portion is described. Another preferred embodiment relates to the use of the noted core component having a multi-layer cover assembly surrounding the core. Various methods for producing such golf ball core components are disclosed.