Abstract: A load bearing, thermally insulating panel for use to cover an ice surface is made up of a plurality of modular, polymeric floor members having a structural dense body structure and a flat upper wall over which a vehicle can travel. Each floor member has an undersurface with integral, downwardly projecting, load distributing, support pillars within a floor member-surrounding, downwardly projecting marginal wall. A polymeric foam insulative layer of substantially lesser density than said floor member and substantially lesser thermal conductivity is molded within the floor member surface surrounding the pillars to fill the space around the pillars and the space between the pillars and marginal wall.

Abstract: A method of manufacturing an injection molded object having an outer shell with a front face and a light transmitting assembly molded into the outer shell which assembly is visible from the front face. The method includes the following steps. Supporting a light transmitting assembly on a mold projecting tool which is closable with a mold cavity tool having an interior wall which defines the front wall of the outer shell. Forming narrow passages through the light transmitting assembly to connect its front and rear faces. Closing the mold to position the front face of the light transmitting assembly adjacent the interior wall of the mold cavity tool while leaving a narrow peripheral recess therearound in communication with the narrow passages.

Abstract: A process for making injection molded articles having a substantially smooth outer surface and a foamed core by injecting a molten thermoplastic into a mold, and, when the outer surface has formed, injecting a gas under pressure into the mold whereby a limited amount of molten material flows back into the injection unit to create a hollow space in the core of the melt, and releasing the gas pressure to allow the core to foam.

Abstract: The present invention is to improve a laminate molding method and a laminate-molding apparatus for manufacturing molded products that have an external appearance of excellent quality. For this purpose, according to a molding method, by which a mold clamping device (3) laminates sheet of skin material (Mm) and a core resin (200), the tension of the sheet of skin material Mm, which is inserted into a cavity (9) between a clamped fixed metal mold (11) and a clamped movable metal mold (12) and is laminated by the movable metal mold (12), is varied, continuously or in a stepped manner, in consonance with the insertion amount of the sheet of skin material (Mm).

Abstract: A structure of synthetic resin foam has a core layer of thermoplastic resin foam and skin layers of non-foamed thermoplastic resin merged with the core layer, and the skin layers gives rise to increase the mechanical strength of the structure.

Abstract: Methods and systems for forming hinged starch-bound matrices. Starch-based compositions are molded between heated molds in order to form a cellular matrix and also to remove the water from the starch-based compositions in order to form a binding matrix of solidified starch. The molding apparatus is configured to form one or more creases within the hinge area in order to define one or more lines upon which the hinge will bend. The molding apparatus is also configured such that the region of the mold corresponding to the inner surface of the hinge area will transfer heat more slowly to the inner hinge surface, resulting in reduced thickness of the skin of the inner hinge. This increases the collapsibility, or ability of the inner surface of the hinge to fold or buckle, during the bending action. This in turn reduces the bending radius of hinge such that the hinging action exerts less strain on the outer surface of the hinge.

Abstract: A console lid comprises a base having a predetermined rigidity and a skin layer member having an inner layer and an outer layer, which covers the base. A cushioning layer made of foamed polyurethane having a thickness that decreases toward the ends thereof is provided between the top of the base and the skin layer member. The skin layer member which has been trimmed is positioned in a mold and the cushioning layer is positioned so that it is in contact with the skin layer member. A plasticized resin is charged into a mold cavity from a gate to form a base. Excellent soft touch and feel is provided by the resulting composite structure since the cushioning layer, made of a soft material, is provided between the base and the skin layer member in a position where such a soft touch or cushioning is most desirable.

Abstract: A fluoroelastomer polymer foam having a compression set value in the range of from about 8.3% to about 43% and closed cell microvoids having diameters of from about 0.002 mm to about 0.048 mm or less, and a method for foaming a fluoroelastomer polymer comprising the steps of dispersing in a fluoroelastomer polymer to be foamed a phenol-based blowing agent to produce a foaming formulation and curing the formulation at a temperature of from about 250.degree. F. (121.degree. C.) to about 450.degree. F. (232.degree. C.) and a pressure of from about ambient to about 3.0 atm.

Abstract: Inorganic composite membrane containing molecular sieve crystals, comprising a macroporous support to which molecular sieve crystals and modifications thereof have been applied substantially as a monolayer, said crystals and modifications thereof having been oriented so that, toa substantial extent, the pores of the sieve crystals form a significant included angle with the support surface, there being present between the crystals a gastight matrix, at least gastight to a degree sufficient under practical conditions.

Abstract: The invention provides an on-line continuous method for producing a masking film roll to be used in painting, comprising corona-discharging the inner surface of a tubular film of a polyolefinic resin, cutting the tubular film open, folding the film in the lengthwise direction in a particular manner, partly attaching an adhesive tape to the film along its lengthwise one edge in such a manner that the adhesive surface of the tape is made to face the corona-discharged surface of the film and that the thus-attached tape is left to have a non-attached part in its lengthwise direction, and winding up the film around a tubular core to be a roll, provides the masking film roll as produced by the method in which the adhesive surface of the adhesive tape attached to thereto faces opposite to the non-corona-discharged surface of the uppermost layer of the folded film, and provides a tubular film of a polyolefinic resin from which the masking film of the invention is produced and of which the inner surface has been coron

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

Abstract: A unitary, monocoque, injection-molded skateboard (and method of making the same) which is characterized by an elongate composite body with a specific gravity in the range of about 0.75 to about 0.8, and including a foamed structural plastic mass having a distributed differentiated density, and contained within that mass, plural, elongate strands of reinforcing carbon fibre material.

Abstract: A method of producing a surfaced composite panel of cellulosic particulates, such as wood flakes, involves the application of polymer forming foamable material to at least one of the first and second major surfaces of the panel, contacting said at least one of the first and second surfaces with a pressure applying surface to apply pressure thereto, foaming the polymer forming foamable material while pressure is applied and curing the applied foam material to produce a polymeric coating on the panel with the desired surface, which is typically extremely smooth. One or both surfaces may be surface treated in this manner. A skin formed on the surface of the panel is believed to add to the strength and stiffness of the coating on the panel. A wide variety of foaming systems may be used to accomplish this surface treating. By avoiding sanding the surface treated panel, the skin remains intact.

Abstract: The present invention relates to a cushioning composite molded article obtained by forming a cushioning material having a surface material on a rigid substrate integrally, and a process for producing the composite molded article by a simple procedure involving a small number of steps for production, andwhen a rigid-resin molded product is set in a mold and an expandable elastomer is injected, after which the inside of the mold is enlarged to expand the substance,the expanded elastomer becomes a cushioning material and its skin layer becomes a surface material, and the formation of them and the union in a body of them and the rigid substrate, i.e., the rigid-resin molded product can be carried out in one mold in succession, so that the production is easy and that labor and the production cost are saved.

Abstract: A process for the production of products of light cellular plastic with closed cells from a plastic composition containing chemical blowing agent and, optionally, other process-regulative substances and additives, where the plastic composition is processed (kneaded) mechanically in a plastic processing machine to a well homogenized, melted plastic compound, and that the plastic compound is then pressed into a closed cavity, at a temperature above the decomposition temperature for the chemical blowing agent in the plastic compound, in combination with possible decomposition regulative additives.

Abstract: In the molding of boot and shoe heels a foamable plastics molding material is injected into a heel mold and a pressurized gaseous fluid is injected into the heel body after it has formed an outer skin against the mold inner surfaces but before it has fully set in order to displace and compress the foaming material and form within the heel at least one enclosed hollow chamber which provides a different degree of resilience to heel strike forces at the location of the chamber. A plurality of closely adjacent chambers may be provided to obtain the same effect, particularly when the heel is shallow. A preformed member may be placed in the mold to form the heel outer surface and ensure a minimum heel wall thickness at this location. The invention also includes apparatus for making such heels, and the heels when so made. The molded body may comprise a sole with an integral heel part. The enclosed chamber may be vented to the ambient atmosphere or it may be sealed.

Abstract: Shaped microcellular structures having substantially non-cellular skins are produced from reactive liquid polymer systems incorporating thermoplastic microspheres containing volatile materials such as low boiling point halogenated or non-halogenated organic materials. Use of thermoplastic microspheres encapsulating such volatile materials facilitates the removal of the shaped foamed structure from molds, eliminating the need for release agents. Various products based on this process, such as bathroom fixtures, bicycle and wheel chair tires, shoe soles, and automotive parts, are provided.

Abstract: A method for making a novel, relatively low-cost loudspeaker cone assembly with an integral suspension rim. The method is for making a cone assembly wherein a cone body having an outer free edge is placed within an open female mold having an annular channel configured to form the suspension rim with the free edge of the cone exposed to the channel. A predetermined quantity of liquid plastic is deposited into the channel of the open mold. Next, the mold is substantially closed by a male die to seal the cone body adjacent its outer free edge. The liquid plastic is then cured under specific pressure and temperature conditions, over a selected interval, so that the resulting annular suspension rim is integrally impregnated into the free outer edge of the cone body and forms high density closed-cell outer skin surfaces in an integral sandwich construction with a low density closed-cell inner core, thereby providing improved flexibility, strength and durability.

Abstract: A protector made of thermoplastic resin to which a foaming agent is added is adapted such that no foams are present in the thermoplastic resin forming a predetermined volume area including lock portions mounted on a protector body for integrating the protector body and a lid element but foams are present in the thermoplastic resin forming the area other than the predetermined volume area, whereby a molded part of thermoplastic resin is provided which accomplishes weight reduction and an insured strength at a strength-required area.

Abstract: A process and device for foaming casings, particularly refrigerator casings, with a blowing agent which can form an explosive mixture with atmospheric oxygen during evaporation which reduce the risk of explosion by introducing inert gas into the space in which the foam is to be formed by means of a servo-controlled inlet valve.

Abstract: Provided is a method of making a multi-property polyurethane part by RIM having a surface layer and an interior layer. The surface layer and the interior layer have different properties. The pressure in the cavity of the mold is reduced and a surface forming RIM polyurethane material is injected into the evacuated cavity, whereby the surface layer of the molded part is formed by RIM. An interior forming RIM polyurethane material is injected into the evacuated cavity, whereby the interior of the molded part is also formed by RIM.

Abstract: A foam molded product of a synthetic resin having a continuous hardened surface layer formed uniformly on a part or the whole of its surface during its foam-in-place molding and having a desired thickness. A mold and a process which can make such a product without bringing about any substantial change in an ordinary foam-molding operation. A part of foamable resin particles which are fed into the mold for making the product are caused to contact a mold surface heated to or above the melting point of the particles and melt to form a molten resin layer, and the molten resin layer is hardened to form the hardened surface layer.

Abstract: Expandable styrene polymers containing recycled polystyrene have a content of recycled material of up to 40% by weight, based on the total weight of the polystyrene, wherein, in the course of the polymerization of the reaction mixture, from 100 to 500 ppm of a molecular weight regulator and/or from 0.05 to 1.0% by weight, based in each case on the polymerization solution, of a finely divided polyethylene wax are added.

Abstract: An interior trim panel comprises a flexible polyurethane skin layer, an intermediate resilient polyurethane foam layer and a rigid polyurethane foam substrate. The flexible polyurethane skin layer and intermediate resilient polyurethane foam layer are formed as an expanded thermoplastic urethane (TPU) shell in a slush molding process. The rigid polyurethane foam substrate is then foamed in place on the shell in a substrate forming mold. This produces an environmentally friendly, long lasting interior trim panel that can be manufactured economically without any need for plasticizers or adhesive coatings.

Abstract: The disclosed oriented polyolefin film contains at least one voided layer. The voided layer contains an amorphous void-initiating polymer which, after orienting, is present as a separate particle inside the void. In the process for producing the polyolefin film, a molten blend comprising an olefin polymer and the amorphous polymer is extruded through a die at an extrusion temperature above the glass temperature or Vicat softening point of the amorphous polymer, the resulting film is drawn off on one or more rollers, and is then subjected to stretch orientation, followed optionally by thermofixing and a surface treatment.

Abstract: Apertured plastic films comprise a stretchable thermoplastic polymeric material having a plurality of micro-holes defined by a network of fiber-like elements. The films are produced by directing fluids, especially water, against the upper surface of a starting film in the form of columnar streams in a contact zone, while the film is supported on a backing element. The films of the invention are useful as covering materials for absorbent products such as diapers, wound dressings and sanitary napkins.

Abstract: A RIM process utilizing a reaction product of an MDI containing from 6 to 50% by weight of the 2,4'-isomer and a polypropylene glycol as the isocyanate reactant results in a molded product having excellent low temperature impact properties.

Abstract: It is object of the present invention to provide a method by which a variable property component, such as two-color parts, having the interior covered with a thin film of the surface area is molded from polyurethanes by RIM, eliminating the need for separately applying a mold release agent or colorants to the cavity surface. Greater latitude in design due to varying physical characteristics is provided.

Abstract: An elongate composite structural member and method of making the same which is particularly useful for forming the handle of hand-held striking and prying tools or implements. The elongate structure member comprises a foamed in place molded resin composition core and outer skin layer which is reinforced with intermediate layer of structurally strong, unidirectional oriented fibers. The expanded foam resin, intermediate fiber layer and the expanded foam resin outer skin are bound together by the cured foamed resin composition formed during the molding process to form a strong, integral composite structure.

Abstract: A wood type metal golf club head having a hollow metal head and the cavity within filled with a thermoplastic material produced from a thermoplastic polymer, filler and chemical blowing agent in a manner so that the material in the cavity has a dense outer skin adjacent the surfaces of the cavity and a cellular central area and the finished product reduces the undesirable metallic sound made during hitting.

Abstract: A method of creating large hollow spheres and other shapes and structures produced according to such method, such method including suspending in a zero gravity environment a molten material mixed with a blowing agent which is caused to foam, expanding into a mass wherein the exterior sphere wall is solidified and the interior is hollowed out.

Abstract: The present invention is directed to polyurethane moldings produced via the RIM process. These polyurethane moldings have excellent reactivity, demold properties (at a 30 s demold), and good elongation and tear strength, and comprise the reaction product of an aliphatic polyisocyanate having a viscosity of less than about 20,000 mPa.multidot.s at 25.degree. C. and a NCO functionality of 2.3 to 4.0 with an isocyanatereactive component comprising b1) a relatively high molecular weight organic compound containing at least one of the groups selected from the group consisting of hydroxy groups and amine groups; and b2) a low molecular weight chain extender selected from the group consisting of diols, triols, primary amines, secondary amines, aminoalcohols, and mixtures thereof; in the presence of a catalyst. The OH:NH ratio of the chain extender is from 1:1 to 25:1.

Abstract: A process for molding a semi-rigid integral skin foam which comprising an integral skin having a low degree of foaming and a core having a high degree of foaming. The process includes evacuating a mold cavity to a pressure of from above 50 to 700 Torr; injecting, into the evacuated mold cavity, a polyurethane material which contains a polyol component and an isocyanate component with air bubbles introduced therein by air loading, in the substantial absence of a foaming agent; and foaming the material to fill the cavity.

Abstract: A shaped article of resin disclosed which possesses a two-ply construction wherein the outer side of a core-layer resin foamed at a void ratio in the range of from 30 to 80% is wrapped with a skin-layer resin. This shaped article of resin is produced by a method which comprises injecting a skin-layer resin into a molding mold and subsequently or simultaneously injecting therein a core-layer resin foamed in advance in a molding device.

Abstract: A process for the continuous production of a high modulus article comprising a composite of an oriented plastic material and an oriented particulate material, said process including the steps of:a. continuously forcing an orientable plastics material, while it is close to or at its softening temperature and in admixture with an orientable particulate material, through a converging passage of which the cross-sectional area diminishes in the forward direction of plastic flow, thereby to produce an extrudate;b. deforming the extrudate, while it is maintained at or close to its melt temperature, to produce an oriented, deformed extrudate; andc. cooling the deformed extrudate to preserve the orientation and provide said composite. The foamed and unfoamed composite articles have strength, modulus and density values comparable to typical hardwoods or softwoods.

Abstract: A sun visor having a sun-visor body with a stiffening at or close to the edge of the sun-visor body. The sun visor body and stiffening being comprised of polypropylene particle foam, the stiffening being substantially harder and stiffer than the remaining regions of the sun-visor body. A method and an apparatus for the manufacture thereof are also disclosed.

Abstract: A method and apparatus for producing a molded polyurethane foam without using low-boiling solvents such as Fleon and methylene chloride which present problems when used as a blowing agent. The polyurethane foam has the same good appearance and soft feeling as that produced with low-boiling solvents. A polyurethane foam is produced by injecting a polyurethane material into an evacuated cavity and permitting it to expand so that it flows and fills the cavity, said polyurethane material being composed of 100 parts by weight of polyol component and 0.1-0.6 part by weight of water as a blowing agent. The cavity pressure may be maintained high spontaneously or low while the polyurethane material is flowing in the cavity. When the polyurethane material has reached the final fill position in the cavity, the fore-end of the polyurethane material is discharged from the cavity.

Abstract: Tubes or pipes are engaged on an insert and are fixed thereon in sealed manner by molding a plastics material at least over those zones of said tubes or pipes that co-operate with the insert. The plastics material is molded so as to form a cellular material whose expansion is performed so as to give rise to compression forces on said tubes or pipes that ensure that said tubes or pipes are fixed or sealed onto the insert.

Abstract: A method for producing a skin-formed polyurethane foam molded product, which comprises reacting a high molecular weight active hydrogen compound containing at least 80% by weight of a polyoxyalkylene polyol having from 2 to 8 hydroxyl groups and a hydroxyl value of from 3 to 60 (mgKOH/g) and consisting essentially of from 20 to 100% by weight of the following component (a) and from 0 to 80% by weight of the following component (b), a chain extender and a polyisocyanate compound in a closed molding tool in the presence of a catalyst and a blowing agent comprising as the main component, at least one member selected from the group consisting of water, a heat decomposable blowing agent capable of generating a gas upon heat decomposition and an inert gas:(a) a polyoxyalkytene polyol having from 2 to 8 hydroxyl groups and a hydroxyl value X (mgKOH/g) of 3.ltoreq.X.ltoreq.60, provided that when 3.ltoreq.X.ltoreq.32.5, the total unsaturated degree Y(meq/g) is Y.ltoreq.0.04, and when 32.5.ltoreq.X.ltoreq.

Abstract: A method of molding a plastic part with a controlled density whereby a blowing agent is added to a plastic material and the material is injected into a mold cavity of a mold unit. The interior walls of the mold cavity are maintained at a temperature sufficient to prevent the outer skin of the forming plastic article from producing gas bubbles. The volume of the mold cavity is increased to allow bubbles to produce and uniformly distribute themselves throughout the mold cavity and then a recompression phase is instituted whereby the desired density of the finished plastic article is achieved without voids or aberrations appearing in the surface of the plastic article.

Abstract: Inorganic composite membrane containing molecular sieve crystals, the membrane having a macroporous support to which molecular sieve crystals and modifications thereof have been applied substantially as monolayer, the crystals have been oriented to a substantial extent, such that the pores of the sieve crystals form a significant included angle with the support surface, the membrane has a gastight matrix present between the crystals.

Abstract: A method for applying a closing tape to an extruded foam article is disclosed. The tape is applied immediately after the article is extruded and while the article is still subject to shrinkage, which is common with extruded foamed products. The tape is prestressed and is of a material to alleviate the problems associated with shrinkage. This method is particularly appropriate for applying a closing tape to an extruded polyethylene pipe insulation product which has been longitudinally slit to allow the pipe to be located interior to the insulation. The tape has one side attached to one side of the slit with the other portion of the tape being positioned for closing the slit by engaging the opposite side of the slit. A pressure sensitive adhesive is provided on the tape and a release liner protects the adhesive on the other portion of the tape.

Abstract: A process is disclosed for producing multiple-layer moulded bodies by injection of a laminate (16) composed of an essentially flexible, foil-like surface material (19) such as leather or textiles, and a foam layer (22) laminated on the back side of the surface material. Before the laminate is introduced in the injection mould, a separating layer (17) is applied on the surface of the foam material. The separating layer is composed of a separating agent that contains a mixture of an aqueous rubber dispersion and a aqueous silicone emulsion.

Abstract: Disclosed is a hydrophobic porous membrane with a polymer having fluorinated alkyl side chains held in physical contact with the surface of a polyolefin porous membrane in which the fluorinated alkyl side chains of the polymer are crystallized, as well as its manufacturing process. Also disclosed is a hydrophobic porous membrane with a fluorinated crosslinked polymer from a fluorinated monomer with a fluorinated alkyl side chain and a crosslinking monomer held in physical contact with the surface of a polyolefin porous membrane, in which the fluorinated alkyl side chains of the fluorinated crosslinked polymer are crystallized, as well as its manufacturing process. These porous membranes use polyolefin porous membranes having a higher mechanical strength and lower costs than the fluorinated polymer porous membranes and still provide superior hydrophobicity over polytetrafluoroethylene type membranes.

Abstract: A lightweight contoured base for a seat cushion is produced by first forming a shaped lightweight foam core with a void corresponding to the ischial tuberosities of a user and then forming a sandwich assembly by placing a layer of foam or foamable material against both upper and lower surfaces of the shaped lightweight foam core to form a sandwich assembly. The sandwich assembly is then molded to produce the finished contoured base for a seat cushion.

Abstract: A foamable composition useful for rotational molding, is provided. The composition advantageously includes an ethylene vinyl ester copolymer as an additive. The additive beneficially has a higher melt index than the base resin of the composition.

Abstract: The use of solutions of zinc carboxylates having 8 to 24 carbon atoms in aliphatic polyamines having molecular weights of from 131 to 500 having a total of 2 or 3 primary, secondary and/or tertiary amine nitrogen atoms as additives for the formation of a compact surface in the production of molded foams having a maximum gross density of 500 kg/m.sup.3 from organic polyisocyanates, polyether polyols, chain lengthening agents, water and optionally other auxiliary agents and additives.

Abstract: A process for the production of fluorochlorocarbon-free, urethane-containing, soft-elastic, semirigid or rigid moldings having a cellular core and a compacted peripheral zone and an essentially pore-free, smooth surface involves reactinga) an organic and/or modified organic polyisocyanate withb) at least one relatively high-molecular-weight compound containing at least two reactive hydrogen atoms, and, if desired,c) a low-molecular-weight chain extender and/or cross-linking agent,in the presence ofd) a blowing agent,e) a catalyst,f) at least one amorphous, microporous silica gel which preferably has a mean pore diameter with a frequency of occurrence of more than 40% in the range from 0.1 to 10 nm, a pore volume of from 0.15 to 1.8 ml/g and a BET surface area of from 200 to 900 m.sup.2 /g, and, if desired, further additives andg) assistants,in a closed mold with compaction.

Abstract: A heat-resisting porous membrane comprises a porous polyolefin membrane having a crosslinked copolymer held on at least a part of the pore surfaces thereof, the crosslinked copolymer being composed of a monomer (A) comprising at least one multifunctional (meth)acrylate and a monomer (B) comprising at least one monofunctional (meth)acrylate having a hydrocarbon radical of 5 to 20 carbon atoms; and the heat-resisting porous membrane can be hydrophilized by additionally having a crosslinked polymer thereon. These heat-resisting porous membranes can be used in hot water for a long period of time without deteriorating the mechanical properties inherently possessed by the matrix of the porous membrane.

Abstract: A method of creating large hollow spheres and other shapes and structures produced according to such method, such method including suspending in a zero gravity environment a molten material mixed with a blowing agent which is caused to foam, expanding into a mass wherein the exterior sphere wall is solidified and the interior is hollowed out.