Abstract: A number of different methods for applying a layer of cushioning material to a surface of an article are provided, whereby the thickness of the cushion layer can be controlled to a high degree of precision and the profile of the cushion layer can also be controlled and varied depending upon the application.

Abstract: A method of forming a resin composite part utilizing a mold surface for mitigating post-cure machining of the resin composite part. The method provides for forming a resin preform having a peripheral geometry similarly sized and configured as a configuration of the mold surface. The mold surface is sized and configured to receive the resin preform. The resin preform is then cured to form the resin composite part with the resin composite part being confirmed to the configuration of the mold surface for mitigating post-cure machining of the resin composite part.

Abstract: An industrial process fabric is embossed in a device, such as a continuously operating two-roll calender having a preselected embossing pattern. The roll(s) of the calender may alternatively themselves be engraved or etched to provide the embossing. Embossing takes place with controlled temperature, pressure, speed and gap (between the rolls) settings. The fabric may be a forming, press, dryer or TAD fabric used in paper and pulp production, pulp forming fabric or an engineered fabric used to produce nonwoven textile products by meltblowing, spunbonding, hydroentangling or air laid needle punching.

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 is proposed for the fabrication of parts with large dimensions formed of a skin (10) and stiffeners (12, 16) such as aircraft fuselage segments made of a composite material with a thermoplastic matrix. After stiffeners have been made separately by lay-up, consolidation and shaping, these stiffeners are placed on a tooling (23) and the skin (10) is simultaneously fabricated and assembled to the stiffeners (12, 16) by diffusion welding. More precisely, the skin (10) is laid up and continuously consolidated by the lay-up head (36) such that the required part is obtained directly.

Abstract: A method of manufacturing hollow, fiber reinforced thermoplastic composite articles, such as a pressure vessel, is disclosed. The thermoplastic binder is chosen to bind the reinforcing fibers together, to provide strength, and to provide ease of manufacture. The method includes placing a preform with an inflatable core into a mold, pressurizing the inflatable core, and heating the mold to enable the thermoplastic binder to melt and distribute throughout the preform, binding the reinforcing fibers. The article is then cooled and removed from the mold, resulting in a hollow molded article. The inflatable core may be removed from the article and reused, or the core may become an integral part of the finished article.

Abstract: A nonwoven textile formed of first fibers and second fibers. The first fibers are standard polyester staple fibers and the second fibers are staple fibers of a blend of polyester material having a melt temperature below the material of the first fibers and above the mold temperature of a subsequent molding process. The nonwoven textile has a base area and a pile area extending from the base area. The pile area is the combination of first fibers and second fibers oriented generally perpendicular to the planar direction of the textile. The base area is a knitted portion of the first fibers and the second fibers. The nonwoven textile can also include a cover area being a knitted portion of the first fibers and second fibers disposed on the pile area opposite to the base area.

Abstract: A polymeric and fibrous laminate is preferably formed of a polyolefin having fillers, such as ground glass, shredded cloth, polypropylene, scrap urethane, or other materials which are heated, mixed, and made into a high viscosity gelatin mass. The polyolefin is combined with a fibrous material in the form of a veil of some type such as Trevira (or other synthetic material), glass (such as fiberglass or other mineral origin materials), or natural fibers, or combinations thereof. The laminate advantageously enhances retainment of fasteners when inserted into the laminate and superior adhesion properties to bond to other substrates that would normally not bond to recycled or virgin polyolefins.

Abstract: A method for forming a compound material by intermittently heating and pressurizing a composite material reinforced by fibers. The method is made up of a pinching step of pinching and fixing the upstream end and the downstream end of the composite material; a heating/pressurizing step of heating and pressurizing the pinched and fixed composite material intermittently; and a moving step of releasing the compound material and sending the material to the downstream direction after termination of the heating/pressurizing step; during the pinching step, tension toward the downstream advancing direction is provided to the downstream end of the composite material, and during the moving step, the amount of movement of the compound material at the downstream side is set to be greater than the amount of movement of the compound material at the upstream side, thereby straightening the fibers in the compound material linearly.

Abstract: A nonslip member in which a large number of nonslip convexes are fixed to an upper surface of a base fabric performing an anchoring action, and the nonslip convexes are made of rubber. By engaging a male mold and a female mold with each other, a large number of small pieces coincident to a shape of through holes of the female mold are punched out from a plate-like material. By pressurizing and heating each small piece between a punching convex and a mounting base while engaging the male mold and the female mold with each other, the small piece is bridged and fixed to the base fabric to serve as a nonslip convex.

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 method of vulcanizing an object formed of unvulcanized rubber, in which the unvulcanized-rubber formed object is vulcanized by pressing and heating by mold means, comprises disposing a fiber sheet member on a surface of the unvulcanized-rubber formed object and vulcanizing the unvulcanized-rubber formed object by the mold means.

Abstract: A method of making a panel by depositing a first extrudate into a mold cavity and pressing the first extrudate with a mold core to form a skin layer. The skin layer is cooled inside the mold cavity. A core material is loaded in the mold cavity onto the skin layer. A second extrudate is deposited into the mold cavity and onto the core. The second extrudate forms a structure layer. The mold core is pressed against the structure layer so that the structure layer forms around the core. The pressure of the mold core against the structure layer also presses the core into the skin layer. The structure layer and the skin layer cool while the mold core is pressed against the structure layer and the core material and the skin layer to form a panel. The panel is removed from the mold cavity.

Abstract: The method provides for forming a supporting structure of the steering wheel, the structure having a metal core and an outer cover layer of polymer material; for each portion of the structure to be covered with valuable material (e.g. brier), two curved preformed half-shells of multilayer composite material are formed of such shape and size as to fit, facing each other, on opposite sides about the corresponding portion of the structure, so as to define a substantially continuous, tubular shell; the portion of the structure is wound, over the outer cover layer, with at least one layer of cloth impregnated with a polymer resin and to which the preformed half-shells are applied; and polymerization of the polymer resin, conducted in a heated mold, ensures adhesion of the half-shells to each other and to the structure.

Abstract: Disclosed is a process of forming a prepreg material having substantially no voids. According to the process of the invention, the reinforcing material is heated to a temperature above the temperature of the impregnating resin. The prepreg formed has substantially no voids and does not require lengthy consolidation when formed into useful articles.

Abstract: A silicone gel sheet is heat-molded from a silicone gel composition comprising metal oxide magnetic particles and a thermoconductive filler. The sheet has a high electromagnetic wave absorbing property at a frequency ranging from 500 to 800 MHz. The hardness of the composition after hardening treatment is set in the range of 10-95 when measured with an ASKER F-type hardness meter. The metal oxide magnetic particles used here can be either Mn—Zn ferrite or Ni—Zn ferrite whose average particle diameter is 1-50 &mgr;m. For the thermoconductive filler, a metal oxide, aluminum nitride, boron nitride, silicon nitride, or silicon carbide can be used. In the silicone gel molded sheet, an electroconductive mesh is embedded in one surface layer of the silicone gel layers while the other surface is provided with adhesiveness.

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: 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 mold for molding a composite article has an upper half mold, a lower half mold having a base and a core mounted on the base, and a pressure plate. A plurality of holes are formed in the upper surface of the pressure plate, and springs are placed in the holes. A laminated sheet formed by laminating woven fabrics is placed on the core, and the pressure plate is put on the laminated sheet so as to press a part of the laminated sheet against the core by its weight without creasing the part of the laminated sheet. When joined to the lower mold, the upper mold compresses the springs to compress the part of the laminated sheet firmly between the pressure plate and the core, and then bends the laminated sheet along the side surfaces of the core so that the laminated sheet is shaped in a predetermined shape.

Abstract: Bicycle frame components without laps made by a method comprising; shaping a fluid-removable core in the general form of the component, placing a flexible inflatable bladder around the core, wrapping over the assembly of core and bladder at least one ply of fiber impregnated with a curable resin, forming a cured part by inflating the bladder while the assembly of core, bladder, and impregnated fiber is in a mold to force the plies against the inner surfaces of the mold, such that compaction of the fiber against the mold is predominantly from the bladder inflation and not from the core, and heating to cure the resin to form a cured part, removing the bladder and the fluid-removable core from the interior of the cured part by disintegrating the fluid-removable core with a fluid sufficient to allow removal of the core and the bladder.

Abstract: A method and system for capturing support materials in carrier frames in the manufacture of seat components for chairs including moving the support material to an openable mold press forming a mold cavity for the carrier frame when the mold press is closed, shaping the support material, and molding the carrier frame to capture the shaped material in the carrier frame. In one embodiment, the support material is stretched as it is moved to the mold press, and/or in the mold press before molding the carrier frame. Excess support material is removable from an outer side portion of the carrier frame after molding the carrier frame and before discharging the carrier frame and support material captured thereby from the mold press.

Abstract: A method and apparatus for manufacturing a preform component for a golf club head composed of a plurality of plies of pre-preg material is disclosed herein. The preform component is preferably a face component, a crown component or a sole component, composed of a plurality of plies of pre-preg material. The apparatus preferably has a plunger head attached to a pneumatic cylinder for compressing the plies of pre-preg sheets within a mold cavity configured to define a preform component.

Abstract: A method for forming an absorbent article having an absorbent pad assembly with an outer fluid-contacting surface including discrete portions of different absorbency is provided. At least first and second absorbent pad materials are helically wound adjacently about a shaft member whereby at least a portion of each of the first and second absorbent pad materials includes an outer surface exposed portion.

Abstract: A method for forming convexities and/or concavities on cloths for a garment at almost entire portions of the garment or any desired portion of the garment without any substantial limitation from a design point of view. The method for forming a garment having convexities and/or concavities which can expand and contract in both the weft and wrap directions like a knitted fabric. Cloths including thermoplastic fiber are cut into parts of the garment, the parts are sewn in a shape of the garment. The garment is overlaid on a thermo-shrinkable cloth. They are sewn together with stitches of water-soluble threads. The sewn cloths are heated under dry heat and without applying any pressure to the cloths so as to permit the thermo-shrinkable cloth to shrink and form convexities and/or concavities on the cloths of the garment. The water-soluble threads are solved and removed, and the cloths of the garment are separated from the thermo-shrinkable cloth.

Abstract: A thermal interface material for interfacing with at least a first surface. One embodiment of the thermal interface material includes a plurality of thermally conductive, malleable fibers arranged in a pattern. The fibers contact each other so as to reduce air gaps and fill irregularities when the fibers are compressed against the first surface.

Abstract: A vehicle headliner having a panel formed of a compressed and molded thermoplastic polymer fiber batt, wherein the fibers are thermally fused together at a multiplicity of locations to impart to the panel a self-supporting rigidity to allow the headliner to retain its shape while also rendering the panel highly deformable and resilient to allow the panel to be bent during installation and thereafter resiliently recover its original shape, is prepared by a process in which improved loft retention of the batt is achieved by appropriate selection of heating parameters and/or selection of polymeric fibers. Also, a process for achieving reduced plastic deformation and improved mechanical properties by modifying the crystallinity of the binder fibers of the batt is disclosed.

Abstract: A method of making a molded track for use with a snowmobile having a suspension system equipped with slide rails consists of a series of steps that include preparing a mold press having a stationary inner mold and a movable outer mold with the inner mold displaying one or more rows of peripherally spaced recesses having a given shape, inserting in the recesses a series of slide bearing elements each having a generally flat portion having a shape corresponding to the shape of the recesses, laying one or more layers of rubber and fabrics on the inner mold and vulcanizing the rubber to form a molded track whereby the slide bearing elements are integrally formed with the molded track with one face of the flat portion of the elements being exposed so that it is frictionally contacted by a slide rail during use of the snowmobile.

Abstract: A molding method and apparatus capable of reliably removing a molded product without deformation even if the product has a shape difficult to be removed, such as a shape having a plurality of vertical portions. The method of molding a product by using a film sheet, includes the steps of: adapting to operate a pair of film pushing rings disposed facing upper and lower metal molds of a molding apparatus for thermally molding a product by using a film sheet, independently from the upper and lower metal molds; attracting and attaching a molded product to one of the upper and lower metal molds; fixing the ring on the side of the one metal mold; attracting and attaching a pickup jig to the molded product in tight contact therewith, the pickup jig having a surface shape matching the surface shape of the molded product; releasing the attraction and attachment by the one metal mold and moving the pickup jig to displace the molded product from the one metal mold; and moving the fixed ring to an original position.

Abstract: A method is provided for fabricating an implantable prosthesis for repairing a defect in a muscle and tissue wall, the prosthesis having a first surface which is convex and a second surface which is concave. The method includes steps of providing a first template having a predetermined concave shape; providing a second template having a predetermined convex shape; placing a piece of implantable flexible mesh between the first and second templates; heating the mesh to a predetermined temperature for a predetermined length of time so that the mesh retains the predetermined shape; and removing the mesh from between the first and second templates. In another aspect, a package is provided for storing a resilient, preformed implantable prosthesis having a first surface with a concave shape and a second surface with a convex shape.

Abstract: A composite molded product has a main body molded of a base material of a thermoplastic resin and defining at least one through opening. A porous skin material is integrated with the main body by thermal fusing. At least one rib is formed on the surface of the skin material at a position corresponding to the position of at least one through opening. At least one rib is integrated with the main body through porous structure of the skin material.

Abstract: A method of producing a carbon-carbon part having a filamentized composite fiber substrate is provided. A substrate having a plurality of discontinuous filamentized fibers and a binder that binds said filaments together to form a composite substrate is provided, and carbon atoms are deposited onto the filaments at a predetermined temperature so that the binder is removed completely from the filaments and replaced with carbon atoms to from a dense carbon-carbon part.

Abstract: A screening screen assembly for a vibratory screening machine including an apertured plate, and a subassembly of an undulating support screen and fine screening screen and finer screening screen bonded to each other by a fused plastic grid and bonded to the apertured plate. A method of fabricating a screening screen assembly for a vibratory screening machine including the steps of providing a support screen, superimposing a plastic grid onto the support screen, superimposing a finer screening screen onto the fine screening screen, applying heat and pressure to the superimposed screens to fuse the plastic grid and thereby form a flat bonded laminate subassembly by causing the fused plastic grid to permeate the fine screen and the finer screen and the support screen, forming the bonded laminate subassembly into an undulating shape, providing an apertured plate, and bonding the undulating bonded subassembly to the apertured plate.

Abstract: A compression molded fixed angle carbon fiber centrifuge rotor and method for forming the centrifuge rotor are provided. My prior art technique of compression molding is utilized in which a frustum fixed angle rotor body is formed between mold parts. As before, sample tube aperture cores are clustered from the apex end of the mold in that array which duplicates the intended number, size, and angularity of the sample tubes desired in the finished rotor. The bottom boundary of the rotor mold has no longer has a substantially planar boundary; instead the bottom of the rotor mold is supplied with a series of scallops, these scallops being equal in number to the sample tube aperture tubes. The shape at the bottom boundary of the rotor is maintained to give a substantially uniform thickness between the sample tube apertures and the exterior bottom surface of the rotor. Sufficient thickness of material is maintained to resist natural load of sample within the sample tube apertures.

Abstract: A golf club shaft is made from sheets of carbon fibers in a thermoplastic matrix. A method and apparatus are also set forth for making a golf club shaft in a substantially voidless manner. An improvement in vibration dampening is obtained.

Abstract: A fiber-bond type ceramic material 4 is produced by using as raw material fibers 1 inorganic fibers of Si—M—C—O synthesized by melt spinning polycarbosilane, then infusibilizing the produced threads, and firing the set threads, forming from the raw material fibers a woven fabric 2 having all the fibers thereof extended perpendicularly or obliquely relative to the direction of compression during the course of a hot-press fabrication at a weaving step 12, heat-treating the woven fabric in the air, thereby preparing a woven fabric of oxidized fibers 3 provided with an oxide layer on the surface thereof at an oxidizing step 14, and subjecting the woven fabric of oxidized fibers to a hot-press fabrication while compressing the fabric in the direction of the compression thereby causing the oxide layers on the surface to adhere fast to each other and form a matrix at a hot-press step 16.

Abstract: A mold for molding a composite article has an upper half mold, a lower half mold having a base and a core mounted on the base, and a pressure plate. A plurality of holes are formed in the upper surface of the pressure plate, and springs are placed in the holes. A laminated sheet formed by laminating woven fabrics is placed on the core, and the pressure plate is put on the laminated sheet so as to press a part of the laminated sheet against the core by its weight without creasing the part of the laminated sheet. When joined to the lower mold, the upper mold compresses the springs to compress the part of the laminated sheet firmly between the pressure plate and the core, and then bends the laminated sheet along the side surfaces of the core so that the laminated sheet is shaped in a predetermined shape.

Abstract: A rib of a composite material for a box structure such as an airfoil has, in an integral structure, a web and flanges formed so as to extend along opposite longitudinal side edges of the web. The web is provided with a plurality of parallel first ridges or beads formed so as to extend across the web and to protrude outward from the outer surface of the web, and each of the flanges is provided with a plurality of parallel second ridges formed so as to extend across the flange, to protrude inward from the outer surface thereof and to merge into the corresponding first ridges. The structure eliminates causes of wrinkles and provides an increased strength.

Abstract: A method for the production of a porous, sound- and heat-insulating shaped element, in particular for lining of sound- and/or heat-emitting vehicle components, by shaping and solidifying a bonded fiber fabric made of natural fibers mixed with a thermoplastic binder in a press mold. The binder is crosslinked uniformly in all regions of the porous shaped element to produce a shaped element featuring a formaldehyde emission of less than 2 ppm due to the replacement of conventional resins with the thermoplastic binder.

Abstract: In a process for forming contours in aramide flat structures, in particular textile flat structures made from aramide fibers, contouring is performed by molding in a temperature range of 180-300.degree. C. and a press pressure range of 4-8 bar (400-800 kPa). The flat structures contoured by molding are suited in particular for the manufacture of antiballistic women's protective clothing as well as of antiballistic helmets. The effectiveness against penetration of bullets and splinters is not affected by the molding process.

Abstract: A method for compression molding a composite, fiber reinforced wheel. The strength, stiffness and reliability of the wheel is maximized so as to resist failure under high shear and other mechanical loads by controlling the orientation of non-metallic fibers which run through the wheel. Substantially all of the fibers in an inner bearing housing of the wheel extend circumferentially therearound, substantially all of the fibers in a cylindrical outer attachment flange run in a radial direction with respect to the wheel, and substantially all of the fibers of an intermediate rim run in an axial direction. During compression molding, some of the axial running fibers of the rim are forced towards and interspersed among some of the fibers which run circumferentially around the bearing housing so as to establish a wave-shaped mechanical interlock at the interface therebetween.

Abstract: A method for producing a fibre reinforced three-dimensional product comprises depositing of long fibers in a mould consisting of a frame in which a carrier net for the fibers is suspended. The individual layers of a formed plane laminate are positioned in such a manner that only a first end is secured at a frame side. Said first ends are secured at different frame sides. In this manner it is possible, in a pressing procedure giving the product is three-dimensional shape, to obtain a virtually even distribution of the fibres, even in areas which are subjected to the longest move away from the plane original laminate. In this manner sound well-defined properties are obtained in the three-dimensional product formed.

Abstract: Methods of making thermoplastic articles having integral projections extending from a surface thereof. The methods utilize a mold plate having a top side, an underside and a cavity extending from the top side to the underside for forming the integral projection. The methods utilize an air escape passage for allowing escape of air from the cavity in the mold plate during the pressing operation. At least a portion of the molding operation is conducted while the temperature of the entrance to the air escape passage is below the molding temperature of the thermoplastic material being molded.

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: An unsaturated polyester resin composition for molding comprising (A) an unsaturated polyester resin, (B) a thickening agent containing powder of a thermoplastic resin as the effective component thereof in an amount of 20 to 120 parts by weight per 100 parts by weight of the unsaturated polyester resin, (C) a liquid polymerizable monomer in an amount of 30 to 120 parts by weight per 100 parts by weight of the unsaturated polyester resin, and (D) a curing agent; SMC and BMC prepared by adding (E) a reinforcing material to the composition; and a process for molding the SMC and the BMC at a low temperature under a low pressure. The unsaturated polyester resin composition of the present invention can be converted into SMC in a short time. The obtained SMC has an excellent storage stability, can be molded at a low temperature under a low pressure, and provides a molded product exhibiting low shrinkage, excellent surface smoothness, a large strength, and a large modulus.

Abstract: A method and apparatus for heating fiber reinforced thermoplastics in sheet form in contact heating means, in which the thermoplastic is heated between bands in the space between two heating means which can be pressed against it and is at the same time held between an upper and a lower sheet-like or filament-shaped restraining means, which is respectively arranged between the thermoplastic and the band. After heating up, the thermoplastic is taken out of the heating zone together with the restraining means and bands, the bands firstly being detached from the thermoplastic, while the restraining means continue to bear against the thermoplastic, and subsequently the restraining means are detached from the thermoplastic.

Abstract: A method of producing a porous film comprises subjecting a fibrous material comprised of fibers of a film forming material to conditions of heat and pressure to covert the fibrous material to a porous film. The method allows the production of film material having substantially uniform pore sizes. For example, the pore size distribution of the film may be such as to have a ratio of maximum pore size:mean flow pore of less than 1.2, e.g., less than 1.1.

Abstract: A high pressure laminate is made of several layers of paper, including from bottom to top core sheets, a decor sheet and an overlay sheet. The core sheets are either composed of cellulose fibers or composed of 30 to 90 weight percent cellulose acetate fibers and 70 to 10 weight percent cellulose fibers. The core sheets are respectively coated with either a lamination polymer or a plasticizer. The decor sheet is composed of a mixture and a conventional amount of paper making dye. The mixture comprises 30 to about 90 weight percent cellulose acetate fibers, 10 to 70 weight percent cellulose fibers and 0 to 20 weight percent fillers. The decor sheet is coated with a plasticizer. The overlay sheet is composed of cellulose fibers and is coated with a lamination polymer. Upon application of heat and pressure to the several layers a laminate is formed having thermoplastic properties, improved postformability and a significant reduction in the release of volatile organics during formation.

Abstract: A process to make a profiled disposable absorbent product is disclosed. The disposable absorbent product has a first sheet, a second sheet and a fibrous core. The core is disposed between the first and second sheets and both sheets are joined to each other along a continuous or discontinuous line. The process comprises the steps of joining the first sheet to the second sheet along a line following at least part of the periphery of the core with a distance to the core of 3 mm to 8 mm; and calendering the core between the sheets in a calender to approximately uniform density, the calendering being such that the core expands along its periphery and thereby reduces the distance of between the edge of the core and the line joining the first sheet to the second sheet by 1 mm or more. The process provides absorbent articles with very small distances between the core and the line of joining the topsheet and backsheet of the absorbent article.

Abstract: A method is disclosed for forming a motor vehicle dash insulator. The method comprises providing an acoustical absorber proximate a first mold half, and providing a second mold half having first and second ends. Barrier material is delivered into the second mold half from a first location in the second mold half and generally toward either the first end or the second end of the second mold half. The delivery of the barrier melt is interrupted, and redelivery occurs from a second location different from the first location and generally toward either the first end or the second end of the second mold half. The mold is closed to bond the acoustical absorber to the barrier material.

Abstract: A method for manufacturing a shaped panel from a continuous length of an expanded mat. The method includes transporting an expanded mat on a conveyor. The conveyor includes side chains and a plurality of spaced apart slats, which extend transversely between the side chains, on which the expanded mat is supported. The side chains and the plurality of slats define a plurality of openings in the conveyor. A length of the expanded mat is confined and shaped between a male mold and a female mold by moving the male mold and the female mold into mating relationship through one of the plurality of openings in the conveyor.