Abstract: A method of making an interior trim panel for attachment to structure of a vehicle includes the steps of placing a trim insert into a cavity of an apparatus and over a first seal thereof. The method also includes the steps of loading a retainer over the trim insert to sandwich the trim insert between the retainer and the first seal and closing the apparatus. The method further includes the steps of filling the cavity with a plastic material and introducing steam into the apparatus to expand the plastic material to form a substrate and bonding the substrate against the trim insert to form an interior trim panel.

Abstract: Methods are taught for manufacturing a press molded article (1) that comprises a profiled substrate layer (10) and a foamed layer (20). A substrate material (12) may be press molded with a foamable material (22) under pressure in order to join or attach the foamable material to the substrate material. In addition, a profile may be imparted to the substrate material during the press molding step, thereby forming the profiled substrate layer. After the press molding step has been completed, the foamable material is foamed and expanded, to thereby form the foamed layer. A skin material (32) optionally may be applied to the foamable layer before the press molding step. Optionally, embossed patterns may be imparted to the skin material during the press molding step, thereby forming an embossed skin layer (30) that is attached to the foamed layer.

Abstract: A first injection mechanism of an apparatus for molding articles injects coating material into a cavity defined in a clamped mold, thereby forming a predetermined coating on the inner surface of the cavity. After the coating material is injected into the cavity, a decompression mechanism lowers the pressure in the cavity through at least one vent. After the coating is formed on the inner surface of the cavity, a second injection mechanism injects molding material into the cavity. When the pressure in the cavity is being lowered, an opening-closing mechanism opens the vent. Before or during the injection of the molding material, the opening-closing mechanism closes the vent.

Abstract: A molding process and apparatus which improves on and simplifies the manufacturing apparatus for forming of laminated plastic parts. There is provided a main press having upper and lower mold parts which define a mold cavity corresponding to the laminated part. The upper mold part is movable into an open booking position so as to cooperate with an opposed injection molding tool associated with a partial injection molding press for injection molding of a backing layer therebetween. A thin skin can be formed in the open lower mold half of the main press. A quantity of foamable urethane is deposited in the open lower mold half over the skin. The upper mold half is then moved into closed position with the lower mold half, and the urethane reacts to fill the cavity and join to the opposed backing layer and skin to create the laminated part.

Abstract: A method and apparatus for making a formed laminate (20) discloses an applicator (42) for depositing a quick reacting foamable liquid mixture (36) onto a transfer member (38) from which the reacted foam (40) and any foamable liquid mixture that has yet to react is transferred onto a flexible sheet (28). Relative movement of a pair of contoured mold surfaces (74,76) of a mold (68) toward each other compresses the flexible sheet (28) and the foam while the foam is in a transitory state (41) after substantial completion of expansion and before substantial curing has taken place such that it is still viscous. This compression provides a collapsed foam layer (30) and forms the foam as well as the flexible sheet (28) to provide the formed laminate (20). A liner (32) is also provided on the opposite side of the collapsed foam as the flexible sheet.

Abstract: A method and an apparatus for manufacturing a polyurethane foam injected with strand mats. After a polyurethane foam solution is sprayed on the strand mats, the strand mats are moved upward and downward by prominences and depressions and then intermittently pressed by a pressing device, thereby the air in the strand mats being exhausted to the outside. Therefore, the polyurethane foam solution uniformly permeates into the strand mats. As a result, the insulating effect and mechanical strength of the polyurethane foam are increased, uniform surface with no air spaces is obtained, the mechanical properties are made uniform, and shrinkage, cracking, distortion and the like are prevented under a super-low temperature such as less than −165° C.

Abstract: A manufacturing method of a polyurethane foam injected with strand mats and a device for increasing the volume of the strand mats. The method comprises the steps of: increasing the volume of each of the strand mats to weaken the cohesion between glass fibers in each of the strand mats; continuously supplying and transferring the volume-increased strand mats; spraying a polyurethane foam solution on the continuously transferred strand mats; and foam molding the polyurethane foam solution in which the strand mats are immersed, into a polyurethane foam. Because the cohesion between the glass fibers in the strand mat is weakened and the volume of the strand mat is increased, the polyurethane foam solution uniformly permeates into the strand mats. As a result, the productivity of the polyurethane foam is improved and the variations in a variety of the mechanical properties are minimized.

Abstract: A light-weight and impact-resistant composite material formed from a three-dimensional textile structure preform comprising at least three systems of yarns that define a plurality of interstices within the textile structure. A cellular matrix material impregnates the textile structure so as to fill the interstices of the three-dimensional textile structure and to coat at least a portion of the surface area thereof.

Abstract: An automobile interior trim component includes a molded substrate laminated onto a cover sheet including a foam backing and a skin film having a surface texture. The cover sheet is preheated so the skin film is in a melted viscous liquid state above its melting temperature, and the foam backing remains in a solid elastic foam state below its melting temperature. The preheated cover sheet is mechanically pre-molded by a back mold into a front mold. Pressurized air is applied through the back mold, to blow-mold the cover sheet against the front mold, so the melted skin film reproduces a surface texture of the front mold surface while the solid foam backing acts as a buffer and air barrier layer. Vacuum is applied through the front mold surface. The mold is opened, a substrate is introduced, and the back mold then molds and thermally laminates the substrate against the foam backing of the cover sheet.

Abstract: In order to achieve an economical and trouble-free continuous extrusion of plastic hollow profiles having at least one hollow chamber that is filled with foam, the profile tool of an extrusion device is configured in the shape of a pistol. The profile tool comprises a pistol shaft (102) with a melt feed channel (166), which is connected to the melt discharge opening of the extruder (300) and which opens into a melt radial distributor channel (164) that surrounds the lance guide channel (150). The profile tool is also equipped with a pistol barrel (101) comprising a melt ring channel (162), which extends from the melt radial distributor channel (164) to the profile nozzle (160) and comprising a lance guide channel (150), which extends in a continuous manner from a lance inlet (152) to the profile nozzle (160).

Abstract: In a process for producing a polyurethane-foam product molded integrally with an insert, wherein a molded body, including a substrate and a polyurethane-foam molded body being molded integrally with the substrate, is produced, the substrate being disposed in an expansion-molding mold as the insert, a fine groove-shaped polyurethane-foam relief groove and a polyurethane-foam adjuster are formed in an end of the substrate and/or a mold surface of the expansion-molding mold which contacts with the substrate. The relief groove communicates with a cavity of the mold. The adjuster communicates with the relief groove, and has a volume larger than that of the relief groove. The relief groove and the adjuster can control the pressure exerted within the cavity. Polyurethane foam, which is formed by the relief groove and the adjuster, adheres to molded product. Therefore, it is possible to obviate the deflashing operation. An expansion-molding mold therefor is also disclosed.

Abstract: An insulating beverage or food container or sleeve is produced with a foam layer disposed on an inner surface of a paper stock. A polymer shrink film layer is arranged in a position along an inside surface of the beverage container. The foam layer is sandwiched between the polymer shrink film layer and the paper stock and decreases the energy transfer between the beverage and the user's hands allowing the user to hold onto the container for an extended period of time without causing user discomfort or pain. The polymer shrink film layer is produced from a shrink film polymer having a percent shrink in the range of 30 % or less, and more particularly a percent shrink range of 5 to 10%.

Abstract: The invention is a method of making a foam filled honeycomb core structure comprising the steps of: 1) providing a honeycomb core billet; 2) reinforcing the honeycomb core with foam; 3) placing the foam filled billet in mold having a curved mold surface; 4) creep forming the foam filled billet to the general shape of the structure by applying a load to the foam filled billet; and 5) machining the creep formed billet to the actual shape of the structure.

Abstract: A process for manufacturing a cushion made of polyurethane foam covered with a cover comprises the initial step of placing the cover in a mould having the shape of the cushion to be obtained, the cover having a front face forming the exterior decoration layer which is placed against the inside wall of the mould and a rough back face facing towards the inside of the mould. Then a film of thermoplastic material is placed on the rough back face of the cover, the film containing agents reacting with polyurethane isocyanate, the film being initially permeable to water vapor. Then polyurethane is injected into the mould to form said foam by expanding. The film has a plastification capability under the effect of chemical reactions occurring between the material of the film and the isocyanate contained in the polyurethane.

Abstract: An expansion-molded article (foamed body) produced by using foamed and expanded beads, and having open voids has sound absorbing qualities, and can be used as a sound absorbing material. However, a sound absorbing material comprising such an expansion-molded article has been unable to attain a high sound absorption coefficient in a wide acoustic frequency range.

Abstract: The invention pertains to a method for treating foamed plastic particles 32 that are present in pourable form, as well as a device for carrying out the method. The invention is characterized by the fact that the foamed plastic particles 32 are reduced in volume in an evacuated environment and then introduced into a mold 10, 34, 46, 52, 56, in which the foamed plastic particles 32 are subsequently restored toward their original outer shape in a non-evacuated environment.

Abstract: A method and apparatus for fabrication of foam laminates suitable for use in the construction of furniture and case goods are provided. The panel has an upper surface formed from a thermoplastic sheet of material such as PVC. A cavity formed by the interior surfaces of the sheet have suspended therein attachment or mounting hardware which is subsequently encapsulated by an in situ structural foaming step. The resulting laminated panel is useful as a table top, shelving, and as a structural component in a variety of case goods and furniture.

Abstract: An insulating beverage cup or sleeve is produced with a foam layer disposed on an inner surface of a food or beverage paper stock. A polyethylene film layer is arranged in a position between a paper stock layer and an inside surface of the beverage container. The foam layer decreases the energy transfer between the beverage and the user's hands allowing the user to hold onto the cup for an extended period of time without causing user discomfort or pain, e.g. greatly extends the hold time of the paper cup. The exterior surface of the beverage cup remains highly printable and predisposed to high quality graphics both before and after cup manufacture.

Abstract: The object of the present invention is to produce plural resin forms at one time with stability by dividing resin starting material continuously in a short time and with the same residence time into plural parts having desired amounts of resin and discharging to solidify them.

Abstract: A method of manufacturing a headliner assembly for use in the interior compartment of an automotive vehicle comprising the steps of: placing a mold release film onto a concave mold surface of a lower mold assembly for providing a barrier against the mold surface; placing a fiber mat on the mold release film; applying a foamable material directly onto the fiber mat; expanding the foamable material around the fiber mat to embed the fiber mat therein; placing an adhesive film onto a convex mold surface of an upper mold assembly; positioning the lower mold assembly directly beneath the upper mold assembly; moving the upper mold assembly in mating engagement with the lower mold assembly to define a mold cavity between the convex mold surface and concave mold surface; curing the foamable material within the mold cavity; and bonding the mold release film and adhesive film to the foamable material with the fiber mat embedded therebetween.

Abstract: A high-purity carbon fiber reinforced carbon composite formed by a process which entails graphitizing a molded member packed with carbon fibers, which fibers are subjected to a purification process under halogen gas prior to being graphitized and prior to being packed with a matrix of carbon material, and the matrix of carbon material, the carbon fiber reinforced carbon composite having an impurities content of not more than 30 ppm in ash content and satisfies either or both of the following conditions for impurities: (1) V is not more than 0.12 ppm by ICP-OES; and (2) Fe is not more than 0.10 ppm by ICP-OES.

Abstract: A system for attaching architectural molding or insulation sheets to buildings or other structures which uses headed fasteners that bear against strips of substantially rigid material embedded in the molding or sheets that include a foam plastic core optionally covered with a hard base coat of cementitious material.

Abstract: A wire harness comprises a plurality of wires routed along a surface of a trim panel. The wires are encased and secured to the trim panel by a foam polymer. The wires are first routed on a surface of the trim panel. A foam gun including a wire guide and a nozzle is moved along the length of the wires, simultaneously gathering and aligning the wires and spraying a foamable liquid onto the wires. The liquid polymer foams and cures, thereby securing the wires to the trim panel and encasing the wires.

Abstract: A method of easily deforming a plate-shape vacuum insulation material and producing a smaller but highly effective insulation container, comprising steps of inserting a thermoplastic open-celled rigid foam as a core material into a packet composed of gas barrier film, evacuating and sealing the packet so as to produce a vacuum insulation material, heating and softening the vacuum insulation material so as to deform the same, and cooling the vacuum insulation material so as to cure the same, and also a freezing and refrigerating container having Peliter element.

Abstract: This invention relates to a cushioned floor covering article wherein the mat includes a tufted carpet placed on the top side of a foam rubber sheet and at least one foam rubber protrusion integrated within at least a portion of the bottom side of the foam rubber sheet. Such an article provides effective removal of moisture, dirt, and debris from the footwear of pedestrians through the utilization of a carpet pile component. Furthermore, the utilization of a foam rubber backing also allows for either periodic heavy duty industrial-scale laundering in such standard washing machines or periodic washing and drying in standard in-home machines, both without appreciably damaging the inventive floor covering article, such as a floor mat. Additionally, the presence of integrated foam rubber protrusions within the mat structure provides an effective cushioning effect for pedestrian comfort as well as a means to prevent slippage of the article from its contacted surface.

Abstract: An article is made by co-curing a lay up on a composite bond jig of fiber-reinforced composite materials having a lower layer, at least one elongated hollow mandrel of a stiffened graphite fabric having its lower surface adhered to the upper surface of the lower layer, and an upper layer adhered to the top and side surfaces of the hollow mandrel and at least portions of the upper surface of the bottom layer.

Abstract: A method for thermoforming a reinforced article, comprising: providing a reinforced plastic sheet comprising at least one thermoplastic material and reinforcement nanoparticles dispersed within the at least one thermoplastic material, the reinforcement particles comprising less than 15% of a total volume of the plastic sheet, at least 50% of the reinforcement particles having a thickness of less than about 20 layers, and at least 99% of the reinforcement particles having a thickness of less than about 30 layers; preheating said plastic sheet; communicating said preheated plastic sheet to a first mold assembly having a first mold cavity defined by mold surfaces, the mold surfaces corresponding to a configuration of the article to be molded, an amount of the plastic sheet communicated to the first mold assembly being sufficient to form a skin of the article; applying a vacuum to one side of the first mold assembly while concurrently applying pressurized gas to an opposing side of the first mold assembly so as t

Abstract: The present invention relates to a multiple foam substrate of predetermined shape and a method of manufacturing the substrate. The substrate is a multiple foam substrate which may be manufactured by the method with a mold having first and second mold cavities. The method includes injecting a first foam into the first mold cavity sufficiently to fill the first mold cavity and storing the first foam in the first mold cavity for a predetermined time sufficient to form a substantially non-mixing surface on the first foam. The method further includes injecting a second foam into the second mold cavity and onto the non-mixing surface on the first foam sufficiently to fill the second mold cavity. The method further includes storing the second foam in the second mold cavity for a predetermined time sufficient to bond the first foam to the second foam along the non-mixing surface.

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 high performance structural foam is used for stiffening parts such as plastic parts. The foam could be formulated for in-mold use at elevated temperatures or at ambient temperatures for use with previously molded parts. Various ingredients are used to control the properties of the foam.

Abstract: Accordingly, the present invention is a soft tire assembly of a thick elastic layer of a foamed elastomer having an outer peripheral surface and cells in the foamed layer that are open to the exterior through the outer peripheral surface, or a mixture of cells open to the exterior and closed cells, wherein the expansion ratio of the foamed elastomer is from 1.5 to 6.0, and the elastomer has a specific gravity of from 0.5 to 2.0. The layer is mounted on a wheel rim, suitably of a metal, having an outer peripheral surface coated with a resin, and the foamed elastic layer is attached onto and about the outer peripheral surface of the wheel rim.

Abstract: A mold apparatus and method for forming a shaped laminate in one step are provided where the laminate includes a cladding layer and a foam backing layer. The apparatus includes a male mold half matable to a female mold half that define a mold cavity. An inlet is mounted on the mold apparatus for introducing foamable materials into the mold cavity. Edge folding members, carried by one of the mold halves, movable from a retracted position to an extended position, fold the cladding layer over at least part of the edge of the foam backing layer. Trim blades are located adjacent to the edge folding members movable from a retracted position adjacent the cavity to an extended position engaging the other mold half to sever the cladding layer to define the finished shape of the laminate.

Abstract: An automobile interior component having a honeycomb structure is disclosed. The honeycomb structure is bonded to the automobile interior component by inserting the honeycomb structure into the molding apparatus, and then molding the automobile interior component around the honeycomb structure. The honeycomb structure has a sufficient size to allow the automobile interior component to meet certain safety standards, such as head impact collision standards, when the automobile interior component is mounted on the frame of a vehicle.

Abstract: Article made of thermoplastic material, which article is rigid and at least partly heat insulating. The article includes a laminate in at least parts of the article. The laminate includes a first and a second layer of solid thermoplastic material (A) and an intermediate layer of expanded thermoplastic material (B) with an average density of 50-800 kg/m3. The thermoplastic materials (A) and (B) are the same or compatible materials. The article is manufactured according to a process comprising the steps a) forming of a solid outer layer, b) manufacturing of an intermediate expanded layer and c) the appendage of functional parts such as reinforcing profiles, guiding profiles, stacking profiles, hinge parts, pockets, label holders, profiles or holes for automatic handling, locking devices or the like.

Abstract: A corded earplug and a method of making a corded earplug, including providing a flexible cord material. Providing a mold member having at least one mold opening of a shape to produce at least an earplug portion inserting a short portion of the flexible cord material into the interior of the mold opening. Providing plastic material to form the earplug portion, and injecting the plastic material into the mold opening to surround the short portion of the cord material and to integrally form the earplug portion with the short portion of the cord material bonded within the earplug portion.

Abstract: A method for manufacturing a carpet used for an automobile comprises steps of: coating a preheated liquid foamable mixture directly on a back surface of the surface material by a spray system; placing the surface material in a molding die comprising an upper portion and a lower portion, the upper and lower portions defining a space inside the die corresponding to a three dimensional shape of the carpet; clamping the liquid foamable mixture with the surface material between those portions of the molding die, when the liquid foamable mixture coated on the back surface of the surface material has completed a gas reaction thereof but is still in a visco-elastic flowing condition; and changing the liquid foamable mixture into a solid condition, thereby a foamed body layer made of the liquid foamable mixture is molded in three dimension and is connected with the surface material through the back surface thereof.

Abstract: A process for manufacturing a catalyst body for generating hydrogen having at least one thin, large-surface catalyst layer, through which the reaction mixture can be passed includes steps of pressing a copper powder (particularly dendritic copper) to form a thin and highly compressed layer which forms a formed body, sintering, the formed body in a reducing atmosphere so that a net-type carrier structure made of copper is formed, and activating a surface layer of the formed body.

Abstract: The uneven surfaces of wood-based materials such as chipboard may be improved by applying a formable coating material, smoothing and/or modelling the coating material to achieve a smoother surface, and heating the coating material to form closed pores while maintaining the smoothed surface intact.

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 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: A method for manufacturing an E.V.A. foamed sports equipment includes preparing and stirring an E.V.A. foamable mixture, then integrally forming the foamable mixture into a sports equipment blank with a constantly reduced scale, the constantly reduced scaled sports equipment blank being placed in a reduced scaled heat forming mold to be heated at the temperature of 180° C., then opening the reduced scaled heat forming mold after a pre-determined period of time, the constantly reduced scaled sports equipment blank in contact with the air being expanded into a foamed sports equipment blank, then, placing the foamed sports equipment blank and ornamental strips into a constantly scaled pattern generating mold to be heat pressed and melted into a unity, the generating mold being evacuated so that the periphery of the foamed sports equipment blank is attached to the pattern generating mold so as to form a foamed sports equipment product with a precise knurl pattern being formed thereon.

Abstract: An automotive interior trim product, for example a headliner, and method of producing such a product. The product comprising an energy management element which is adapted to be secured to an automotive interior to provide an energy management function. The energy management element is fabricated from a material comprising an array of fused or bonded tube-like members, and comprises a one-piece unitary structure with zones of differing physical properties. The zones of differing physical properties provide different levels of energy management which are matched to the requirements of the interior. The differing physical properties and so differing levels of energy management in the different zones being produced by molding of the unitary element. Alternatively, and/or in addition within the fused array differing types of tube-like members may be used in the differing zones. Such differing types of tubes may have different wall thicknesses, different diameters/dimensions.

Abstract: A plastics molded part with a soft-feel surface as a layer of soft material molded on the surface of the part. The edges of the soft material are protected and hidden by a rib which is part of the molded part, which extends in a plane which runs generally parallel to the contour of the part in the region of the rib and which is substantially coplanar with the surface of the part not covered by soft material. The soft material is placed in the mold prior to plastics injection. During injection, the soft material is compressed against the outer mold wall. On ejection from the mold, the soft material recovers and expands so that its outer surface is flush with the outer surface of the rib.

Abstract: Described is a method of forming and curing high internal phase emulsions (HIPEs) into shaped three dimensional foam implements. In general the method uses the steps of: providing a HIPE, depositing the HIPE into a mold cavity having a predetermined three dimensional shape, curing the HIPE in the mold cavity to form a HIPE foam, and stripping the HIPE foam from the mold cavity to form the three dimensional foam implement. The molded implements are widely useful as components in absorbent articles, toys, insulation, and other uses where a combination of low density and tridimensional shape are desired.

Abstract: A composite material includes five distinct layers of material: two thin outer layers or panels, a central rigid core and intermediate foam layers on both sides of the core which fill the regions between the core and outer panels. The core can be a wide variety of material but is preferably a rigid foam or wood having resin or epoxy impregnated fiber or fiber filled outer skins. An array of apertures extends through the core. During the fabrication process, the apertures facilitate cross flow of the foam and ensure even distribution thereof. As a finished product, the foam filled apertures ensure positive location and retention of the core within the foam. The foam may be any suitable injectable foam but is preferably a composition which remains resilient upon curing as such foam more readily accommodates dimensional changes between the layers due to, for example, ambient temperatures changes.

Abstract: A process for making a padded armrest on an interior door panel of an automotive vehicle includes the step of conforming an outer cover to a contoured surface of a mold. A blocking device is then placed against a portion of an inside surface of the outer cover and a rigid substrate if formed against the inside of the outer cover and about the blocking device providing a support structure for the outer cover. The blocking device is then removed from the outer cover and mold to form a cavity in the substrate defined by a portion of the outer cover. A resilient foam pad is inserted or formed within the cavity to provide local padded support to the outer cover.

Abstract: A process for making a padded armrest on an interior door panel of an automotive vehicle includes the step of conforming an outer cover to a contoured surface of a mold. A blocking device is then placed against a portion of an inside surface of the outer cover and a rigid substrate if formed against the inside of the outer cover and about the blocking device providing a support structure for the outer cover. The blocking device is then removed from the outer cover and mold to form a cavity in the substrate defined by a portion of the outer cover. A resilient foam pad is inserted or formed within the cavity to provide local padded support to the outer cover.

Abstract: A method and apparatus for making a composite article that includes a soft trim component employs a pair of mold halves, wherein a suitable skin material is sprayed onto a first mold cavity surface to obtain an in-mold coating, and a substrate is positioned between the mold halves such that a first area of one side of the substrate is located in opposition with the in-mold coating. A sprue defined in the second mold half, in opposition with the other side of the substrate, directs injected foam through an aperture in the substrate and into a gap defined between the one side of the substrate and the in-mold coating. A portion of the first mold half includes a layer of a sealing material that is harder than the substrate material to thereby eliminate the need to otherwise trim the overmolded soft trim component upon release from the mold.

Abstract: A process for injecting a urethane material into a mold cavity from a gate to mold articles. Urethane molded articles are produced by first forming a coating film layer on the inside surface of a mold cavity. Next, a first urethane material containing pigment is injected into the cavity. Finally, a second urethane material containing more pigment than the first urethane material is injected into the cavity.

Abstract: There is now provided a method for producing a product comprising plastic foam in an automatic molding machine. The method comprises providing a woven fabric on at least one surface of the mold cavity, with the woven fabric comprising a fabric having a fine-mesh woven fabric ply that faces the interior of the mold cavity upon assembly and a coarse-mesh woven fabric ply that is disposed adjacent at least one surface of the mold cavity and beneath the fine-mesh woven ply upon assembly to support the fine-mesh woven ply. The method further provides for introducing beads comprising plastic foam into the mold cavity; contacting the beads with a gaseous heat transfer medium, such as superheated steam; introducing the gaseous heat transfer medium into the mold cavity; flowing the gaseous heat transfer medium along a first surface of the mold cavity; and removing gaseous heat transfer medium along a second surface of the mold cavity; and removing the finished product from the mold.