Abstract: A method of molding a headrest of automotive seat comprises the following steps. First, a bag shaped flexible outer skin member is prepared, has an elongate slit formed therethrough. A part of a stay member is inserted into the outer skin member through the slit and set relative to the outer skin member. A given biasing force is applied to longitudinal ends of the slit so that the slit is stretched in longitudinally opposed directions and thus caused to take a closed position. Then, an injection nozzle of a foamable material feeder is put into the slit by expanding the slit against the biasing force. A foamable material is poured into the outer skin member, and the material feeding is stopped when a given amount of material is fed to the outer skin member. The application of the biasing force to the slit is continued until the material is sufficiently cured.

Abstract: A process for fabricating an article having a rigid foam core and a resilient outer plastic shell by extruding a heated thermoplastic material to form the shell, partially hardening the extruded plastic shell, injecting a liquid foam material into the interior of the partially hardened plastic shell, and cooling the shell and the liquid foam material to fully harden the plastic shell and the foam under conditions which cause the article to have a predetermined shape and size.

Abstract: A skin foam-in-place skin material is prepared by stitching a plurality of skin forming pieces into a predetermined shape. End edges of the skin forming pieces made of moquette skin are overlapped one upon another. The overlapped portion is joined together by over-lock stitches at a stitching pitch ranging from 1.5 to 3.0 mm using a single needle and three threads along the end edge.

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 process for the production of composite sheet bodies by back-foaming a flexible facing with a polyurethane foam forming reaction mixture. This polyurethane foam is characterized by a density of less than 300 g/l, preferably from 20 to 150 g/l, and optionally contains isocyanurate groups. Suitable flexible facings include those having a thickness of less than 10 mm, preferably less than 2 mm. This composite bodies produced by this process are suitable for use in the automobile sector as self-supporting components. Conventional stiffening elements are not necessary to produce these self-supporting composite bodies.

Abstract: A process for manufacturing a wheel of a roller skate with a hub and a wheel body fixed around the hub is disclosed. The wheel body has a soft inner portion which is mounted around the hub and a hard outer portion which is fixed around the soft inner portion. The process includes: connecting two ends of a rubber tube in order to form a molding loop; forming a radial hole in the molding loop; charging a foamable rubber material into the molding loop via the radial hole; allowing the foamable rubber material to foam and fill the molding loop in order to form the inner portion of the wheel body; mounting the molding loop around an outer periphery of the hub; and injection molding a rubber material in a mold in order to form the outer portion of the wheel body around the molding loop and the outer periphery of the hub and in order to melt the molding loop and interconnect the foamable rubber material and the outer portion.

Abstract: A vehicle interior trim component, such as a glove compartment or console door, and its method of fabrication includes an outer flexible shell having a peripheral contoured return flap captured within a peripheral gap provided between insert and backing panels of the component. Foam is injected into a space between the outer shell and insert panel and any gases and excess foam are allowed to escape from the foam space into an adjacent overflow chamber in a controlled manner through the gap while the return flap seals the assembly against external leakage of such excess foam.

Abstract: A method of manufacturing an adhesive foamed product for use in a hollow component of a motorcar, includes the steps of mixing an adhesive resin, a foaming agent, a crosslinking agent, a foaming accelerator and a polymerizable monomer to thereby formulate a highly foamable composition, arranging the foamable composition thus formulated in the interior of a hollow component of a motorcar, and heating the foamable composition until it is foamed to have a shape corresponding substantially to the shape of the hollow component.

Abstract: An apparatus for immobilizing and positioning the head, shoulder, and torso region of the human anatomy when in the prone position for radiographic examination or treatment. The device consists of a base board, a face support, a pair head side walls, a pair of shoulder walls, and a pair of body side walls. A foam mixture is applied to the upper surface of the base and the entire device is placed into a large flexible container or bag. A patient's head, shoulder and torso region are placed on the device in a prone position. The patient remains in a fixed position while the foam mixture expands around the patient's body and the apparatus. After a brief period of time, the foam sets or hardens and a mold or template is formed. This mold serves to immobilize the head, shoulder and torso region of the body when in a prone position during radiographic examinations and treatment as well as other procedures.

Abstract: An energy absorbing interior automotive trim part (36) has a shell (42) made from polypropylene sections (62), (68), and (69) divided via partitions (58) and (72) extending from the outer wall (44) of shell (42) and touching the passenger compartment facing wall (46). The shell (42) is blow molded with carpet (74), vinyls and other fabric materials (76) integrally molded to adhere directly to wall (46). After molding, interior section or partial section (62) is filled with a structurally engineered energy absorbing foam (64) to provide an energy absorbing structure which will compress a pre-determined distance while absorbing the compressive force applied.

Abstract: A high impact resistant rotationally molded door and process for molding the door is disclosed in which a hinge member is integrally molded to the door along one edge only. This hinge member forms to the hollow door edge without door warpage during curing and shrinking of rotationally molded plastic door body. Door warpage is avoided by delaying full integral attachment of the hinge member to the door until curing of the injected foam interior which both bonds to the interior of the door and the hinge member. An improved seal and hinge seal is disclosed together with a placed window construction that can include both placement and shaping to meet the special order needs. Further improvements including the expedient of venting a rotationally molded door during the rotational molding process through an integrally molded hinge edge reinforcing member. This same venting scheme is utilized for enabling improved cooling of the door once molding of the hollow door shell has occurred.

Abstract: A process for manufacturing a ski comprises the steps of providing a shell with a substantially U-shaped cross section, a top strap being integrated into the shell, the shell having a base and shanks extending downwardly and outwardly at an angle to the base, placing a ski core in between the shanks, but not contacting either the shanks or the base, placing a bottom strap on and spanning the space between the outwardly projecting ends of the shanks, and filling all hollow spaces between the core, the shell, and the bottom strap with a liquid plastic material to bond the core, the shell and the bottom strap.

Abstract: A structurally rigid biodegradable foam scaffold useful for cell transplantation is provided. The foam can be loaded with nutrients and/or drugs that elute from the foam during transplant to promote growth of the cells. The foam, which features a continuous network of pores, is fabricated using a novel method involving phase separation and consequent expansion upon sublimation of a liquid solvent, preferably naphthalene.

Abstract: A blade for a fan is formed by rotomolding around a pre-positioned support member, part of which extends out of the mold, the support member being shaped, or being provided with one or more projections, which are partly embedded in the plastic material forming a skin of the fan blade. The fan blade is made hollow by this method, but is preferably filled either during molding or subsequently with a hard foam material. A hub is also provided for mounting any fan blades, but in particular those made by the method, in which a hub includes a body portion having a first radial face associated therewith, a plate having a second radial face parallel to the first radial face and spaced therefrom, and a plurality of circumferentially equally spaced depressions facing one another on the first and second radial faces to accommodate the fan blade support members, means being provided to secure the plate to the body portion effective to clamp the fan blade and support members firmly.

Abstract: A headliner assembly for lining a passenger compartment ceiling of a motor vehicle comprising a headliner cover having an exterior surface presenting a major exterior appearance of the headliner assembly and an opposite interior surface, and a body of foamed material adhered to the opposite interior surface of the headliner cover and having central portions thereof with a greater thickness than peripheral portions thereof, the body of foamed material being of generally constant density throughout its extent including the central and peripheral portions thereof.

Abstract: A composite legal type bicycle frame is disclosed which contains a front frame portion and a rear frame portion. The front frame portion contains a central main and a plurality of legs for connecting the central main with various components of the bicycle, and the rear frame portion contains a rear fork, which consists of a left rear branch and a right rear branch. The left and right rear branches are first cured and glued together at respective abutting surfaces thereof to form an integral rear fork before they are adjoined with the front frame portion, via prepregs and using a cocuring procedure. The left and right rear branches are formed to contain cross-shaped matching protrusion and recess, respectively, on the abutting surfaces thereof, so as to enhance the integrity of the integral rear fork. As a result, a great flexibility of design options can be obtained. For example, the rear fork can be connected to one of the legs but not to the central main.

Abstract: An inflatable, self-standing, transparent insulating jacket for a hot water tank is disclosed. The jacket is comprised of an inflatable hood, a platform and an attachment means. The hood surrounds, but is spaced outwardly from, the hot water tank. The hood comprises transparent inner and outer members each defining a cylindrical chamber and having an open end and a peripheral edge surround the open end. The inner and outer member edges are bonded together at or near their respective peripheral edges so as to form an impermeable fluid tight inflatable pocket between the members. A valve is provided on the outer member to inflate and deflate the inflatable pocket. The platform, having an outer diameter greater than the outer diameter of the hood, is disposed beneath the hot water tank. The attachment means, preferably a zipper type fastener, secures the hood to the platform.

Abstract: A process is provided for curing a high internal phase emulsion to form a porous crosslinked polymeric material is provided, comprising the steps of: forming a high internal phase emulsion having at least one curable phase; providing a continuous strip of a polymeric film wherein the polymeric film is incompatible with each of the phases of the emulsion; placing at least a portion of the emulsion continuously on the polymeric film; closing the polymeric film around the film; and curing the emulsion within the polymeric film. Apparatuses to perform this process are also disclosed.

Abstract: A composite structure and method of making the composite structure are disclosed. A reinforcing fabric such as fiberglass is mechanically attached, for example, by stitching to a non-woven polyester fabric. The attached fabrics are placed in a mold with the non-woven fabric facing the inside of the mold. A self-expanding, self-curing foam is filled into the mold in an amount sufficient so that upon expansion in the closed mold, the foam penetrates into the interstices of the non-woven fabric which upon curing forms a bond therewith. The resulting structure can be used in a number of applications wherein the reinforcing fabric is later impregnated, for example, with a resin, and allowed to cure. Typical use of such a structure is as a stringer in fiberglass boat construction.

Abstract: A process for fabricating an article having a rigid foam core and a resilient outer plastic shell by extruding heated thermoplastic material to form the shell, partially hardening the extruded a plastic shell, injecting a liquid foam material into the interior of the partially hardened plastic shell, and cooling the shell and the liquid foam material to fully harden the plastic shell and the foam under conditions which cause the article to have a predetermined shape and size.

Abstract: A molded foam article with an integral skin is produced by blow-molding a parison in a cavity of a metal mold to form a hollow member, filling the hollow member with pre-expanded thermoplastic resin besides before cooling and solidification of the hollow member, and heating the pre-expanded beads to cause the beads to expand further and fuse together. A filler for the pre-expanded thermoplastic resin beads is provided with a cutter for making a hole in the hollow member before introducing the resin beads into the hollow member.

Abstract: This invention produces three-dimensional shapes such as window lineals by first lining a foam die with a continuously moving reinforcing veil. Once the veil is in the foam die, a foam is blown into the die. The foam expands in the die forcing the veil against the die wall. The veil is selected so that the foam never fully penetrates the veil, but adheres to it. The material exiting the foam die is now properly shaped to enter the curing die. Resin is then injected onto the foam core where it penetrates the veil, is cured in the heated curing die and exits as a finished product of a plastic skin adhered to a foam core with a veil sandwiched therebetween.

Abstract: A protective and release coating is applied to the front portion of an artificial eyepiece before it is placed in a mold to form a taxidermy animal head mannikin. The protective and release coating is preferably a latex material that protects the front surface of the glass or plastic artificial eyepiece from scratching or other damage while being placed in a mannikin mold. The mannikin mold defines a cavity surface contoured for correct anatomical features of the animal head mannikin, including the features immediately surrounding the eye. Eye socket recesses in the cavity surface are shaped to snugly receive the front portions of the eyepieces. Indicia ridges or locator sockets may be located around or in the eye socket recesses, to facilitate the proper orientation of artificial eyepieces within the eye sockets.

Abstract: The essence of the technique is to superimpose a shaped elastic membrane/cover over a seat shell and lock the membrane to the edge of the seat shell with a channel-section trim. The uppermost edge of the cover is left temporarily unattached to the seat so an incipiently-reacting foam, mixed in a volume predetermined to be in excess of what is necessary, can be poured between the membrane and the shell. The subject is then seated and the foam expands to provide positive support for the anatomy and fill all the voids between the body's impression in the membrane and the seat shell, thereby making a full-contact mold of the body. Overflow is allowed to escape at the uppermost portion of the seat where it is captured in a bag that also serves to contain noxious chemical vapors. Foam may be of a rigid or resilient type to vary the support and cushion provided.

Abstract: A method of manufacturing a rigid foamed product includes the steps of mixing a metal adhesive resin, a foaming agent, a foaming accelerator, a crosslinking agent, a monomer, and a fibrous material to formulate a foamable composition, arranging the foamable composition thus formulated in a cavity of a formed metal component, and heating the metal component with the foamable composition.

Abstract: A method for producing a plastic molding having a core and a foam with a skin on an outer surface of the core wherein a foaming material is foamed in a space defined between a skin member and the core, disposed within a molding die assembly having an upper die and a lower die includes disposing the skin member which is provided with edge portions that are bent backward to define side portions and engaging recesses provided on the side portions or in the vicinity thereof, on the lower die of the molding die assembly that is provided with engaging projections corresponding to the engaging recesses of the skin member, so that the engaging projections of the lower die are fitted in the corresponding engaging recesses of the skin member to position and hold the latter; disposing the core which is provided with side walls which define a foaming material receiving portion on the die surface of the upper surface of the die assembly, so that the skin member is fitted in the foaming material receiving portion; and pour

Abstract: A method for forming an armrest, wherein there are provided a three-dimensional box-like trim cover assembly having slit and hole formed therein, a frame and a shaft separate from the frame. In the method, the frame is inserted through the slit into the inside of the trim cover assembly, and then, the shaft is inserted through the hole into the same inside of trim cover assembly, so that the shaft is connected to the frame at a predetermined position within the trim cover assembly via a connecting element. Thereafter, such incomplete armrest unit is subject to foaming in a foaming die, to thereby form a complete armrest. The trim cover assembly includes a high-density foam layer and an impregnation preventive film having plural ventilation holes formed therein in order to prevent impregnation of liquid foaming material into a foam wadding layer of trim cover assembly and attain air permeability of armrest.

Abstract: A helmet making process includes the steps of opening the upper die with flash gates; heating the upper and lower dies in a oven with the use of an endless conveying device; inserting shape-molded plastic upper and lower shells respectively into the lower and upper and lower dies; filling a polyurethane mixture into the upper shell; shaking the upper and lower dies; heating the upper and lower dies to allow the polyurethane mixture to be foamed completely; piercing the foamed polyurethane through the air holes in the upper die; removing the semi-finished helmet; cooling the semi-finished helmet in air; cutting off the flashes and projected portions and recessed portions of the upper and lower shells; trimming and surface-treating the semi-finished helmet to form a finished helmet.

Abstract: A tandem motorcycle seat for attachment to the frame of an associated motorcycle has a unitary, rigid, elongated platform member configured to seat upon and be secured to the frame of the motorcycle, and an elongated tandem saddle on the platform member providing drive and passenger seat portions. A backrest for a person seated on one of the seat portions has a depending leg spaced inwardly from the side margins of the saddle which extends through a passage in the saddle into a receptacle on a bracket secured to the platform member. In making the seat, a first layer of a mixture of glass fibers and polyester resin is embedded on the lower element of a mold which is configured to form the platform member of the seat. Hardware is applied on the first layer and a second layer of glass fiber/resin is applied to the first layer and about the hardware so as to encapsulate at least a portion of the hardware in the layers which are then partially cured.

Abstract: A process for producing bodies of polymeric material having an outer shell and a core of foamed material is disclosed. The process includes the steps of: providing a mold having a pair of separable half-molds arranged facing each other; extruding a tubular thermoplastic parison between the half-molds; closing the half-molds around the parison, thereby defining a hollow space between the parison and walls of the mold; injecting into the inside of the parison a thermoplastic polymeric material admixed with a physical blowing agent, the parison expanding into contact with the walls of the mold, and conforming to the shape of the mold; and removing the article form the mold.

Abstract: A polyurethane seat pad having a center seat portion and bank portions therearound is molded by using a mold defining a cavity having a center region corresponding to the center seat portion and side regions corresponding to the bank portions, placing collecting vessels of expanded polyolefin in the side regions of the mold cavity, pouring a foamable polyurethane liquid for low hardness foam into the cavity between said collecting vessels, pouring a foamable polyurethane liquid for high hardness foam into said collecting vessels, and causing the foamable liquids to expand, thereby producing a polyurethane seat pad having the collecting vessels embedded therein. The expanded polyolefin is a crosslinked polyolefin foam having an index of surface wetting of at least 36 dyne/cm. The seat pad in which the bank portions have higher hardness than the seating portion and which is fully durable against repetitive loading can be produced to the desired configuration in a stable manner.

Abstract: The present invention provides a filter medium, which contains an electretized nonwoven web of crimped fibers selected from the group consisting of spunbond filaments and staple fibers, wherein the nonwoven web has a Frazier permeability equal to or greater than about 100 ft.sup.3 /min/ft.sup.2 and a density between about 0.01 g/cm.sup.3 and about 0.095 g/cm.sup.3.

Abstract: An improved wheel construction includes a disc and a rim secured together and which define a radially inwardly facing circumferential cavity in the wheel. In accordance with the present invention, a filler material is disposed in a substantial portion of the cavity to prevent road material or other debris from accumulating in the cavity and causing an out-of-balance wheel condition.

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: A method of making a safety helmet includes using a molding tool having an upper mold cavity and a lower mold cavity. The upper mold cavity is preheated and is then coated with a layer of releasing agent. The releasing agent layer is coated subsequently with a layer of polyurethane lacquer, which is caused by the residual heat of the preheated upper mold cavity to form a smooth film layer. A plastic shell of the safety helmet is disposed in the lower mold cavity. A foam material is injected into the plastic shell before the molding tool is closed. As the foaming process is completed, the molding tool is opened to remove therefrom a safety helmet including the shell, the foam layer formed of the foam material, and the smooth film layer which is formed integrally with the foam layer for providing the user of the safety helmet with wearing comfort.

Abstract: The present invention is an insulation material with improved loft characteristics and methods for producing such insulation. The preferred insulation comprises a multiple layered insulation material with discrete fibers having energy expandable thermoplastic microspheres interspersed and contained therein. The use of expandable microspheres allows for (1) the introduction of unexpanded microspheres into pro-constructed insulation; and (2) expansion of the microspheres within the insulation to a diameter greater enough that the microspheres are retained in place. The insulation of the present invention exhibits many improved properties over conventional insulations, such as improved loft, better thermal insulation, improved compression resistance, and improved resilience.

Abstract: A coextruded multilayer film having increased retention of volatile antioxidants and process for making the film. The multilayer film includes an antioxidant layer containing a volatile antioxidant, said antioxidant layer being semipermeable to the volatile antioxidant; and a barrier layer, impermeable to the volatile antioxidant. The film can be produced on a conventional blown film process with the barrier layer coextruded externally to the antioxidant layer. The barrier layer traps the volatile antioxidant inside the tube of the blown film process, reducing the amount of volatile antioxidant migrating from the film.

Abstract: A seal structure between a leg part 15 of a front lens and a seal groove 12, wherein a seal member 20 is applied into the seal groove 12 formed on a periphery of a front opening portion of a lamp body 10, the leg part 15 of the front lens engaging with the seal groove 12 is secured to the seal groove 12 by a mechanical fastening means (clip 30) to prevent a removal, and the seal member 20 in the seal groove 12 is compressed by the lens leg part 15, characterized in that the seal member 20 is formed of a solid foamed material which foams from an initial fluid state and hardens while keeping elasticity, and which can be stripped off.

Abstract: A seal structure between a leg part 15 of a front lens and a seal groove 12, wherein a seal member 20 is applied into the seal groove 12 formed on a periphery of a front opening portion of a lamp body 10, the leg part 15 of the front lens engaging with the seal groove 12 is secured to the seal groove 12 by a mechanical fastening means (clip 30) to prevent a removal, and the seal member 20 in the seal groove 12 is compressed by the lens leg part 15, characterized in that the seal member 20 is formed of a solid foamed material which foams from an initial fluid state and hardens while keeping elasticity, and which can be stripped off.

Abstract: A footwear insole having an integrated comfort and support pad and method of manufacture is disclosed. The insole is formed of a sheet material having a through opening therein and a cushion bonded to a marginal edge of the opening and to at least one side of the sheet material defining a narrow rim about the opening. The result is an integral, strong and flexible cushion insole suitable for the manufacture of particularly light and thin dress shoes. The insole may alternatively be formed with a cushion which extends in both directions beyond the thickness of the insole and is received on one side of the insole in a complementary recess of an outsole.

Abstract: A bumper construction for vehicles constructed of a single strip of metal roll-formed into a completely enclosed tubular member in which a foamed-in-place material is located in and completely fills only a central section of the tubular member a relatively short distance on each side of the central axis of the vehicle. An apparatus is provided for manufacturing roll-formed bumpers partially filled with a foam-in-place material, the bumpers including material defining a continuous closed section defining an open interior and opposing open ends. The apparatus includes a turntable with a plurality of holders including arms shaped to extend partially into the bumpers, and a plug on the end of each arm configured to block off the open interior of the bumper. The holders are pivotally mounted on the turntable so that a bumper can be slipped onto a selected holder, pivoted to an upright position, and then rotated by the turntable under an injector for dispensing foamable reaction injectable urethane (RIM) material.

Abstract: A method for producing an IC card including filling a confined space with a mixture including a foaming resin, the mixture having not been foamed yet, the space being confined by a frame having cut-out portions on inner edges and at least one through-hole passing through the frame in the lateral direction between the inside and the outside of the frame, a circuit board on which functional components are mounted and having edges fitted to one of the cut-out portions of the frame so that the surface of the circuit board on which functional components are mounted faces inward, the frame and the circuit board forming a substantially flat outer surface, and a thin plate having edges fitted to another of the cut-out portions of the frame with the thin plate opposing the circuit board, the frame and the thin plate forming a substantially flat outer surface; foaming the mixture at a predetermined temperature for a predetermined time, thus filling the confined space with foamed resin, and thus making the foamed resin

Abstract: A method of producing a plastic pin, including a bowling pin, having a cellular and/or porous core that is surrounded by a solid-walled, noncellular and nonporous shell. The shell is initially produced as a whole body in a mold. While the material of the shell is not yet hardened and is still deformable, an insert is introduced into the narrowed neck portion of the shell, in a direction axial relative thereto, in such a way that the insert displaces an inner layer of the shell, dividing the hollow interior of the shell into an upper and a lower chamber and producing a fixed connection with the material of the shell. Material for the core, with such material being provided with an expanding agent, is then introduced into the shell, and after the shell and the core have set, the mold is removed.

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: There is provided an improved process for partially molding a pad onto an instrument panel by partially covering the surface of a panel main body with a surfacing material, and filling a urethane foam under foaming in the space defined between the panel main body and the surfacing material and a mold used for such purpose. In the process of the invention, a mold including an upper die having a core and a lower die having a cavity wall is used, and possible outward falling down of the edge portion formed along the periphery of the surfacing material is designed to be prevented by supporting members which are arranged retractably in the cavity wall of the lower die at the positions along the line where the edge portion of the surfacing material lies. The supporting members retain the edge portion until the upper die is fully closed with respect to the lower die.

Abstract: A method for producing a plastic molding having a foam with a skin on an outer surface of a core wherein a foaming material is foamed in a space defined between a skin member and the core, disposed within a molding die assembly having an upper die and a lower die includes disposing the skin member which is provided with side portions and recessed grooves at the edge portions thereof, on the lower die of the molding die assembly; fitting edge holders projecting from the lower die into the recessed grooves of the skin member; disposing the core which is provided with a recess in which the skin member is received, in the molding die assembly; pouring the foaming material in a space between the skin member and the bottom surface of the core to foam the foaming material; and retracting the edge holders into the lower die during the foaming before the foaming operation is completed. The disclosure is also directed to a molding die apparatus for producing such a plastic molding.

Abstract: A process for improving adhesion of a thermoplastic polymeric resin on a casting surface by using an electrostatic pinning wire in conjunction with a conductive shield. The method includes the steps of extrusion casting a sheet of molten polymer from a die, directing the cast sheet onto a moving, chilled and electrically grounded casting surface to solidify the polymer and extending a conductive wire transverse to a longitudinal axis of the sheet with the sheet between the wire and the chilled surface before the sheet contacts the chilled surface. An elongated conductive uninsulated shield parallel to the wire with the wire between the shield and the sheet is provided and a bias voltage is applied to the wire and the shield. The bias voltage of the wire is in the range of 6 to 15 kV, and the bias voltage of the shield is adjusted to be at least 5 kV lower than the voltage of the wire to maintain a desired current flowing from the wire and the shield to the sheet.

Abstract: A two-stage co-cure method for fabricating a composite article having a box-beam cross-sectional configuration wherein an outer shell portion of the composite article is fabricated and configured in the first stage to function as the tooling for completing the fabrication of composite article in the second stage.

Abstract: A vehicle air bag installation comprises an air bag mounted in a unitary container comprising a molded plastic substrate having an I-shaped slot defining a pair of doors with integral hinges, and a continuous self-skinned polyurethane foam covering adhered thereto during the formation of the covering. The covering has predetermined weakened sections formed along a tear line defined by the slot which rupture during air bag deployment to facilitate door opening. The covering material is an aliphatic or aromatic isocyanate cured low density polyurethane foam having a durometer of 35-60 Shore A. The unitary container is formed by providing a molded plastic container substrate having slots defining the doors, placing the substrate in a mold having a cover, placing a core within the mold to support the substrate. The core has a plurality of upstanding spaced blades projecting into the slots into spaced relation to the mold cover. Urethane foam is injected into the mold and the cover is closed.

Abstract: In molding bonded plastics material, in particular expanded or foamable polystyrene in combination with rigid sheet polystyrene, the rigid material (2) is firstly preformed in a preforming mold (33, 36) while simultaneously separating by a cutter (40) the preformed portion from the rigid sheet of starting material, the preformed portion is transferred (27) to the molding stage (3) while contained in a preforming half-mold (33), foamable material (44) is fed to and is molded onto the preformed portion with sintering and the pulse action of steam (45), and the molded portion (P) is discharged (6). The preforming half-mold (33) is moved alternately between the preforming position (1) and the molding position (3), and cooperates with respective counter-molds (36,41). The scrap is recovered without being involved in the molding stage.