Abstract: For the production of a particularly dimensionally stable cable set, the single conductors(22) of the cable set are initially inserted into a cavity (8) of a foam tool (2) and a foaming material is subsequently filled in. To dispense with involved and expensive hydraulic equipment, a vacuum is generated to press a top half (6) and a bottom half (4) of the foaming tool (2) against each other. For this, vacuum channels (6) are preferably provided, which extend along sides of the cavity (8).

Abstract: A method and an industrial robotic device for uniformly applying coatings at appropriate thickness and pitch upon a surface moves a spray applicator foam dispenser between two parallel tracks. The uniform application of foam at each pass is assured, by accelerating the speed of the foam dispenser at the end of each pass, by providing respective curved uphill distal ends of the tracks, so that the spray applicator foam dispenser moves up the curved distal ends and returns quickly while changing speed tilt and direction at the end of each pass.

Abstract: A process for preparing a multilayered foam article such as an automotive seat is disclosed. A mold is arranged so that the bottom surface of the mold is flat or inclined up to 40 degrees to the horizontal plane. The first liquid foam formulation designed to produce a soft foam is poured into the mold from a mixing head outlet strip-wise across the seating zone of the mold along the line parallel to but near the external wall of the seating zone of the mold. Then, the second liquid foam formulation designed to produce a hard foam is poured into the mold from the same or different mixing head outlet strip-wise across the seating zone of the mold along the line parallel to but nearer to the external wall of the mold than the line of pouring of the first liquid foam formulation. The second liquid foam formulation is then allowed to spread on top of the first liquid foam formulation, the mold is closed and the foames are allowed to rise and cure in the mold.

Abstract: There is a described a cushion element a method for producing same. Specifically, the improved cushion element includes a fastener assembly for mechanical adhesion of a trim cover to the cushion element. The fastener assembly comprises laterally spaced marginal portions which extend longitudinally along the fastener assembly. These margins are embedded in or encompassed by the foam body thereby improving the mechanical “pull-out” strength of the fastener assembly in the foam body.

Abstract: A wall or panel has a thin concrete layer with a cross-sectional contour having protrusions and indentations forming other objects, such as stone work, brick or wood. A reinforcement layer may be affixed to the concrete layer to provide tensile strength and impact resistance to the concrete layer. A foam layer is affixed to the reinforcement layer to further reinforce the concrete layer, and so that the wall or panel is light weight. A second concrete layer or a rigid backing layer may be disposed opposite the concrete layer so that the foam is disposed therebetween. A method for forming the wall or panel includes spraying the concrete onto a mold surface which has indentations and protrusions for forming the other objects. The reinforcement layer is sprayed onto the cured concrete layer. The mold is closed and foam is introduced into the mold.

Abstract: The method of the present invention is particularly suited for making decorative objects in a mold cavity. The method enables one to form a decorative component having an outer elastomeric layer that is integral with an inner layer of foam. Because the chemical formulation for the outer layer and the inner layer is identical, other than the inner layer includes a foaming agent, the decorative component does not suffer from the drawbacks of the previous methods such as, for example, poor adhesion between the elastomeric layer and the foam layer causing delamination of the two layers, sinks or holes in the foam layer leading to imperfections in the elastomeric layer, and bleed through to the elastomeric layer from the foam layer. The method permits the mold to be pre-coated with an in-mold paint prior to the molding process. Coatings can also be applied after demolding the resulting part.

Abstract: A method for creating a hot melt foamed form for an air induction system. A block of thermal mastic elastomer is melted and blended with nitrogen gas to create a foamed material. The foamed material is applied by robotic techniques over a base material on the surface of a polypropylene glass lower shell. After the foamed material cures, a polypropylene glass cover is applied over the foamed material form to create an air tight dust/water seal. The cover does not adhere to the cured foamed material and is removable when service is necessary. The foam material can also be dispensed into a mold and then transferred to the base, allowing for changes in the shape and profile of the foamed material. This method can also be employed to create an isolation pad on an air induction system to absorb engine shock. The thermal mastic elastomer can also be employed to create a seal between the cover neck of an air induction assembly and a mass air flow sensor.

Abstract: A method of manufacturing a composite article includes applying at least one resin impregnated fiber sheet to an inner surface of a forming mold, applying a predetermined mass of a syntactic foam mixture on at least a portion of the resin impregnated fiber sheets, closing the forming mold and heating the mold, the resin impregnated fiber sheets and the syntactic foam mixture to a predetermined temperature for a time sufficient to fully cure the resin impregnated fiber sheet and the syntactic foam to form the composite article. The syntactic foam mixture is formulated so that during the cure cycle, the syntactic foam gels, expands, and starts to cure before the resin impregnated fiber sheets of the outer shell. The expansion of the inner core of syntactic foam forces the fiber sheets of the shell against the inner surface of the mold to accurately reproduce the mold contours.

Abstract: A process for foaming around a peripheral edge area of a cover (10) for a motor vehicle roof, the cover being placed on or in a foaming tool and the foam mass (18) being fed into the foaming tool such that two foam mass fronts are formed which run around the peripheral edge in the peripheral direction and merge with one another or meet one another in the merging area at a side opposite that at which the foam was introduced. The foaming tool is made such that, in the merging area, the cross section of the foam mass is reduced on the side opposite the ventilation side (40) of the foaming tool that is vented relative to the areas (42, 142) which border the merging area in order to prevent inclusion of gas bubbles in the merging area. Furthermore, a cover for a motor vehicle roof is produced which has a foamed peripheral edge area in which two foam mass fronts, which are formed during the peripheral foaming in a foaming tool, merge with one another.

Abstract: The loudspeaker comprises a cone (2) and a beading (4) attached to the cone (2). The beading (4) is composed of a sprayable plastic layer which is soft in its solid state. The manufacture of the loudspeaker is facilitated by a process in which an open negative mold (16) is used in which the cone (2) is arranged and immobilized. Following this, the plastic is sprayed into the open negative mold (16) and the beading (4) is formed as a soft plastic layer which attaches itself to the cone (2).

Abstract: A manufacturing method of a cushion member which has a two-layer structure constituted by an obverse layer portion and a reverse layer portion and has no dispersion of thickness between the obverse layer portion and the reverse layer portion. Side cavities, a first cavity and a second cavity are formed in a lower die and side partitions and a front and rear partition are provided therein. A first raw material foams and flows within the first cavity, and a second raw material flows within the first cavity while being limited by a front and rear flow port with respect to a flow amount and a flow direction and covers over the first raw material so as to flow forward in such a manner as to follow the flow of a flow front end portion of the first raw material. Then, an obverse layer portion and a front edge portion made of the first raw material, and a reverse layer portion made of the second raw material are formed in the first cavity.

Abstract: A composite molded article of light weight and low cost, and producing method thereof, and also, an inner mold and a metal mold which are used for producing a cellular molded article in mold pattern having surface skin and capable to be preheated even in a condition of opening the metal mold so that the molding cycle can be shortened.

Abstract: A method for creating a hot melt foamed form for an air induction system. A block of thermal mastic elastomer is melted and blended with nitrogen gas to create a foamed material. The foamed material is applied by robotic techniques over a base material on the surface of a polypropylene glass lower shell. After the foamed material cures, a polypropylene glass cover is applied over the foamed material form to create an air tight dust/water seal. The cover does not adhere to the cured foamed material and is removable when service is necessary. The foam material can also be dispensed into a mold and then transferred to the base, allowing for changes in the shape and profile of the foamed material. This method can also be employed to create an isolation pad on an air induction system to absorb engine shock. The thermal mastic elastomer can also be employed to create a seal between the cover neck of an air induction assembly and a mass air flow sensor.

Abstract: A process for the manufacturing of floor elements, which floor elements comprise an upper decorative surface and a lower surface, edges intended for joining and a core forming a carrying structure. A mixture of polyols, such as polyester or polyether, crude methylene diphenyl diisocyanate and possibly a small amount of blowing agent in a ratio forming a polymeric resin with a density in the range 600-1400 kg/m3 is injected or cast into a mold, whereby a slightly porous or solid polyurethane core is formed.

Abstract: The present invention provides a method for producing an expanded fiber-reinforced thermoplastic resin molding, the method using a mold comprising a female and male dies and comprising processes for supplying a molten thermoplastic resin containing reinforcing fibers whose average fiber length is maintained at 1 mm or more to between the female and male dies to charge a mold cavity with the molten thermoplastic resin, opening a part or the whole of the mold in the thickness direction of a molding after the charging, and cooling a molding while maintaining a cavity clearance at the thickness of a final molding, the method wherein the mold cavity of the mold is interconnectable to the atmosphere, the method further comprising steps for (a) forming a solidified layer in the surface of the molten thermoplastic resin charged in the mold cavity, followed by (b) breaking at least a part of the solidified surface layer, introducing the air through the broken part concurrently with or after the breakage, and opening a

Abstract: Injection molding encapsulation processes for packaging an object or objects in microcellular foamed material, comprising the steps of providing a mold having a mold cavity, positioning at least one object in the mold cavity, providing a packaging material, introducing a fluid into the packaging material under conditions sufficient to produce a supercritical fluid-packaging material solution, introducing the solution into the mold cavity, and converting the solution into a microcellular foamed material. Such processes are advantageously employed in encapsulation of electronic or electrical components. Packaged objects produced therefrom may be completely or partially encapsulated.

Abstract: This invention relates to a cushioned dust control mat article wherein the mat comprises at least two distinct layers of rubber, one comprising foam rubber, the other comprising solid rubber. The solid rubber layer is present over the foam rubber layer on the side of the mat in which at least one integrated rubber protrusion is present to provide cushioning characteristics. The solid rubber layer acts as a cap or barrier for the foam rubber layer, particularly over the integrated protrusion or protrusions, in order to provide a mat which is resilient, will not easily degrade in its modulus strength after appreciable use and/or washing within industrial cleaning processes, and will not exhibit appreciable cracking or breaking, particularly within the integrated protrusion(s), after standard use for pedestrian traffic. A method of producing such an inventive cushioned floor mat article is also provided.

Abstract: This invention relates to a foam molded part made of a soft foam-like material, in particular for an upholstery element of an automotive seat. The foam molded part has at least two spatially separate zones which are designed in one piece, each preferably having different material properties.

Abstract: A seat pad with a fastener is manufactured by forming a groove in a mold, arranging a longitudinal end of the groove, disposing the fastener on the mold to have the surface of the fastener facing the groove, curving a longitudinal end of the fastener to protrude in the mold, and injecting a forming synthetic resin into the mold.

Abstract: A method for forming a headliner assembly includes forming a main body having a periphery, and a shape corresponding to a desired shape of the headliner assembly; positioning the main body in a mold having a recess; closing the mold; and injecting foam into the recess to simultaneously form an energy absorbing member and join the energy absorbing member to the main body proximate the periphery of the main body.

Abstract: A method for making a resilient material includes providing a particulate polymer, discrete pieces of foam and a plasticizer. The polymer, foam pieces and plasticizer are mixed and disposed in a mold. The mold is heated to cause melting of the polymer without melting of the foam. After coating of the melted polymer, a heterogeneous resilient cushion is formed with gelated polymer surrounding the discrete foam pieces.

Abstract: A seal plug (10) for closing a aperture in a panel includes a cover cap (12), a set of seal plug retaining tabs (32, 34, 36, 38) extending from a bottom face (16) of the plug and a set of guide elements (60, 62, 64, 66) extending from the bottom face of the plug. The guide elements (60-66) disposed on the bottom face of the seal plug define a first axially orientated lead-in surface. The retaining tabs (32-38) disposed on the bottom face of the seal plug define a second axially orientated lead-in surface. The first and second lead-in surfaces cooperate making the seal plug easy to install. A thermoexpanding plastic sealing ring (30) adapted to soften and expand upon heating to a temperature of about 250° F. is disposed on the bottom face of the seal plug. The seal ring expands and softens in an oven enabling the seal plug to become firmly bonded to a surface defining an aperture.

Abstract: A method for foaming or foam-coating components is used for foaming hollow cavities of double-walled or multiple-walled components or foam-coating component parts with decorative surfaces so as to improve haptic properties of component parts. A material is introduced or applied in an unfoamed state to be foamed through the use of microwave energy. In order to achieve high dielectric losses and to ensure that the heat effect is evently distributed and essentially restricted to the material to be foamed, the material is adjusted in a polar manner by addition of certain substances such as conductive soot. Reflecting agents are used to improve the distribution and effect of the microwaves. The method ensures fully foamed hollow cavities and foam layers of uniform thickness. A foamable material for foaming or foam-coating components is also provided.

Abstract: In a preferred embodiment, the invention is a non-deflatable tire assembly having a hollow toroid-shaped flanged insert, a flexible body molded around the insert to form a tire, and at least one rim onto which is mounted the tire. The flange of the insert extends toward the central axis of the insert, and is used to attach the tire to the rim(s) via bolts through matching holes within the flange and rim(s). The flexible body may be made of a foam polyurethane matrix formed of a combination of polyol and polyisocyanate, while the flanged insert may be made of a high density polyethylene. A tough, flexible, and abrasive-resistant layer of polyurethane elastomer is preferably formed around the flexible body to define sidewalls and treads of the tire.

Abstract: The invention comprises a fully continuous process for shaping a high internal phase emulsion (HIPE) with a polymerizable continuous phase into dry foam, comprising 1) providing a high internal phase emulsion (HIPE) comprising (a) at least 70 percent by volume of an eternal phase comprising one or more polymerizable monomer; (b) a surfactant in an amount effective to produce a high internal phase emulsion; and (c) an internal phase; 20 depositing the emulsion onto a lower moving support substrate; 3) leveling the emulsion to a desired thickness above the support substrate; 4) polymerizing the monomers by running the emulsion and the lower moving support substrate through a heating zone for a time sufficient to polymerize at least 75% of the monomer in the HIPE by the end of the heating zone; and 5) drying the polymerized HIPE in a drying zone for a time sufficient to produce a foam having greater than 50% of the internal phase removed.

Abstract: Molded, soft composite articles such as seat cushions are made by (a) applying a composition which forms a soft elastomer to all interior walls of an open mold, (b) introducing a composition which will react to form a low density, high resiliency, flexible foam under molding conditions into the mold in a manner such that the foam-forming composition will be substantially completely within the elastomer-forming composition; (c) closing the mold (i) prior to introduction of the foam-forming composition or (ii) at some point during or subsequent to introduction of the foam-forming mixture but before foam formation is completed and (d) allowing the foam-forming mixture to form a foam. The composite articles produced by this simple one-step process are characterized by good cushioning characteristics, good abrasion resistance and good mold reproducibility. This molding process generates less waste and requires less labor and equipment than current commercial processes.

Abstract: A composite component is produced with a foamed surface. A substrate part having a surface to be coated is placed into a mold, a layer of an unfoamed or merely pre-foamed, foamable material is applied to the surface of the substrate part at a first temperature, and the foamable material is expanded at a second temperature or a sequence of temperatures that are higher than the first temperature. The expansion is effected with a chemical blowing agent or a blowing agent mixture, so that the foamable material in the expanded state fills an intermediate space between the surface of the substrate part and a molding surface of the mold and, on the one hand, bonds with the surface of the substrate part and, on the other hand, comes to bear against the molding surface.

Abstract: A foamed rubber obtainable by a process including the steps of:

Abstract: A method of molding a plastic shell having an outer pliable skin layer and a foam backing layer comprises casting a first skin layer portion from wear resistant material in a first casting sequence for those areas of the panel susceptible to high wear and in a second casting sequence casting self-skinning foamable material against the remaining portion of the mold surface and over the first-cast skin layer portion to develop, simultaneously, the remaining outer skin layer portion of the shell and a foam backing layer which extends across the entire skin layer.

Abstract: In order to decrease the height of a solid foam body produced from a pool of foaming liquid as the foaming liquid solidifies into the solid body, the height of a bottom mold face is decreased by sloping the mold face so that there is less liquid at higher locations of the mold face than at lower locations. This technique is especially useful in making seals for filter elements, wherein the filter elements are annular in horizontal cross-section so that less sealing material occurs adjacent the downstream clean side of the filter media comprising the filter element than adjacent the upstream dirty side of the filter media. In a particular application, a filter element with a frustoconical filter media has one end sealed by a rising volume of solidifying urethane foam so that more foam is adjacent the outside surface of the filter media than the inside surface, and so that the foam also forms a peripheral gasket adjacent the outside surface.

Abstract: When molding of a heat-curable resin such as unsaturated polyester resin and the like is conducted by means of the casting method, concavities in the molded product generated as a result of the curing shrinkage of this resin are prevented.

Abstract: A floor, wall, roof, or ceiling of a building is made of specially adapted beams and overlying panels. The beams have a layer of foam material on their edges. The foam material can include a resiliently compressible material, a thermally insulating material, or a material which possesses both of these properties. The panels are positioned over the beams so that the foam material is sandwiched between the beams and the panels. When the panels are fastened to the beams, the resiliently compressible foam material partially compresses, thereby filling any gaps which may form between the beams and the panels. The resiliently compressible foam material thus prevents relative movement between the panel and the beams which would otherwise produce squeaks. When the foam material includes thermal insulating material, it forms a thermal barrier between panels and beams, especially metal beams, thereby eliminating various drawbacks of construction using metal beams.

Abstract: A method of molding a plastic shell having an outer pliable skin layer and a foam backing layer comprises casting a first skin layer portion from wear resistant material in a first casting sequence for those areas of the panel susceptible to high wear and in a second casting sequence casting self-skinning foamable material against the remaining portion of the mold surface and over the first-cast skin layer portion to develop, simultaneously, the remaining outer skin layer portion of the shell and a foam backing layer which extends across the entire skin layer.

Abstract: This invention relates to a method for producing cellular molded article in mold pattern of synthetic resin having surface skin which is used, for example, as an automobile interior trim material or the like and a mold pattern for producing thereof. This invention aims to provide a method for producing cellular molded article of synthetic resin having surface skin which has good production efficiency and which comprises that cellular molded article of synthetic resin obtained by cellular molding of expanded beads in which poor melt bonding does not occur and thermoplastic resin skin material united with this cellular molded article of synthetic resin which has excellent appearance without residing beads pattern on its surface, and a mold used for producing thereof.

Abstract: In a method of producing an upholstered article, at least first and second cover portions of an upholstery cover are molded in mutually spatially separated relationship. The cover portions are fitted to a core portion to form the upholstery cover therearound. Defined between the outside surface of the core portion and the inside surface of the upholstery cover is a defined gap into which a coating material is introduced. The coating material on hardening joins the upholstery cover to the core portion.

Abstract: An automotive lamp which includes a lamp body, a gasket disposed between the lamp body and an automobile body panel for sealing a back side of the lamp, a seal leg projecting from the lamp body for attaching thereto the gasket, wherein the foamed gasket is molded integrally with a tip end part of the seal leg.

Abstract: A method for producing a composite bathtub having at least one steel shell and at least one acrylic shell which are solidly joined to each other. A deep-drawn acrylic blank is first reverse-drawn over a core. An outer shell mold is then placed over the acrylic blank, at a certain distance from the acrylic blank. Once the outer shell mold and the acrylic blank are sealed off from each other, a reaction resin is injected into the space between the two shells. After the reaction resin has set, the outer shell mold is removed and the steel blank is positioned. The space between the steel blank and the acrylic blank is re-sealed and a polymer foam is injected into this intermediate space. Once the polymer foam has cross-linked, the composite bathtub is complete. One advantage of the method of this invention is that the acrylic shell and the steel exterior of the composite bathtub do not have to be identical in shape.

Abstract: A method for making an expanded sole, in which a blank is preliminarily molded as an unexpanded form in a preliminary mold and is then subjected to a product inspection, followed by a high temperature heating to undergo a reaction for expansion and cross-linking in a high-temperature mold, is disclosed. In the method, the unexpanded blank is formed with a thickness greater than and with a cross-section smaller than those of the mold cavity of the high-temperature mold via the preliminary mold, thus facilitating placement of the blank into the high-temperature mold and venting air easily from the high-temperature mold. In addition, the bottom surface and the lateral surfaces of the blank are formed with flutes via the preliminary mold so as to assist in ventilation during molding of the blank in the high temperature mold.

Abstract: A method for making an improved absorber entails the loading of reticulated foam loaded with radar absorbing material and the forming and curing of the loaded foam in a mold on which vacuum is impressed prior to curing of the foam so that the foam expands and thereby experiences a substantial reduction in density of the resulting absorber structure.

Abstract: A method of making a door trim panel assembly for attachment to an inner panel of an automotive vehicle includes the steps of placing a door trim substrate into a cavity of a mold and placing at least one component into the cavity against the door trim substrate. The method also includes as an alternative of pre-joining the at least one component to the door trim substrate. The method also includes the steps of filling the cavity with a plastic material. The method further includes the steps of introducing steam into the mold to expand the plastic material to form a carrier and bond the carrier against the at least one component and door trim substrate to form a single door trim panel assembly.

Abstract: A composite tank for containing liquid oxygen and the method of making the same wherein a water-soluble mandrel having the desired tank configuration and a cylindrical A method of making a composite tank for containing liquid oxygen configuration of the mandrel and an outer boss conforming to the configuration of the inner boss, the bosses each having a tubular portion for receiving the protuberance on the mandrel and a spherical portion. The mandrel and the bosses are first coated with a nickel coating. The mandrel is then wrapped with graphite fibers wetted with an epoxy resin and this resin is cured. A layer of insulating foam is then applied to the tank and cured. The insulating foam is machined to a desired configuration and a layer of aramid fibers wetted with a second epoxy resin is wrapped around the tank. The second resin is cured and the water soluble mandrel is washed from inside the tank.

Abstract: A method for manufacturing a plastic board comprising a sandwich-like structure comprises the steps of: (1) providing an injection moulding device with a mould which comprises at least two mould parts displaceable relative to each other by displacing means, which mould parts in a closed first extreme position bound a mould cavity connecting onto an injection unit and in an open second extreme position release a formed board for removal; (2) providing foaming means for causing foaming in the mould cavity of plastic injected into the mould cavity; (3) providing blocking means for temporarily rendering the foaming means inactive; (4) energizing the blocking means; (5) energizing the injection unit in the first extreme position of the mould; (6) ending the energizing of the blocking means; (7) ending the energizing of the injection unit; and (8) displacing the mould parts relative to each other.

Abstract: A method for forming products such as simulated leather including one or more layers from thermoplastic, thermosetting or elastomer materials all formed by slush-moulding, comprising: forming in a slush-moulding mould a first layer of compacted material representing the exposed layer of the finished product, on said first layer forming a second layer of expandable material by further slush-moulding, completing with heat the consolidation of said layers by gelling and expansion of said second layer, the free face of which has an irregular shape. To the layered material thus formed is coupled a support of rigid material without discontinuity points or regions between them by filling every possible interspace.

Abstract: A manufacturing method of diaphragms for use in electroacoustic transducers simultaneously joins an edge and a diaphragm body upon molding the diaphragm body through an injection molding with a set of mating molds for forming the diaphragm body, with the edge of a cell-structure disposed on one of the mating molds, the edge being preliminarily molded and cut into a predetermined shape, and with the other mold mated with the one mold.

Abstract: A method for forming an automotive instrument panel having a concealed door comprising a series of steps. A plastic parison is extruded to form the substrate layer of the instrument panel. The parison has first and second walls. The parison is placed within a mold and the first wall is contacted with the second wall to form a hinge. The area of contact forms a bond between the first and second walls. A different portion of the first and second walls are contacted to form an opening path. The opening path intersects the hinge. The opening path usually has a thickness much less than the thickness of the first and second walls to form an easily fracturable area. The door swings on the hinge to open. A elongated section of material on the second wall, enables the second wall to wrap along the hinge when the door is opened.

Abstract: An apparatus for forming an interior panel for a vehicle door includes mandrels which hold rolls of vinyl laminate and fiberglass reinforcing mat and from which sheets of vinyl laminate and reinforcing mat are pulled in overlying relation with respect to each other. The vinyl and mat sheets are tacked together, cut to a predetermined length by a cutting mechanism, and moved into a heater by a pin-chain conveyor system. In the heater, the vinyl and mat are heated until the vinyl, which is supported at its edges by the pin-chain conveyor, sags a sufficient amount to indicate that the vinyl is sufficiently softened. The heated vinyl and mat are then moved to a vacuum mold part and thereafter a vacuum is applied to draw the vinyl to a molding surface of the vacuum mold part. A vacuum assist, carried on a carrier, engages the mat and heated vinyl within the vacuum mold part to press the mat into the heated vinyl to partially embed the mat into the vinyl to secure the mat to the vinyl.