Abstract: Ski upper- and lower-surface constituting materials are set in position in a mold provided with a space appropriate for the dimensional distribution of the padding for the ski. The ski upper-surface constituting material is arranged so that a resin sheet of ABS resin, etc. constitutes the outer surface of ski. The inner upper surface of the upper mold piece is formed in a curved surface having, for example, grooves. A foamy resin is injected to fill the space between the ski upper and lower constituting materials. The foaming pressure raised by the foamy resin will press the resin sheet against the inner upper surface of the upper mold piece with resulting deformation of the resin sheet. Thus one may obtain a ski which is provided on its upper surface with projections.

Abstract: A method for manufacturing a predetermined shape of molded plastics, comprising the steps of introducing a foamable shell forming material in molding dies, introducing a hard core forming material having a foaming agent on the shell forming material, clamping the molding dies together, and heating both the material located in the molding dies by an induction heating.

Abstract: Gaskets are formed in container closures fabricated from polyolefin resins exhibiting substantially no response to heat activation by radio frequency electrical energy by introducing a vinyl chloride plastisol containing a vinyl chloride polymer resin and a plasticizer having a loss factor in the range of 0.1-12 into the closure. The closure is preheated to 55.degree. to 100.degree. C. by conventional means and then the plastisol is fused in the closure by exposure to a field of radio frequency electrical energy.

Abstract: The molded shell of an article, while still warm from being molded, and while remaining within the mold or fixture in which it has been created, for instance by blow-molding of a parison of polyolefin plastic material into contact with the mold walls, is filled with a fluid, settable foaming plastic material, for instance polyurethane. This may be done by injecting the foaming mixture directly into the cavity of the shell. In this manner time, labor and materials are saved, and the resulting product is characterized by better adhesion of the foamed core to the internal wall surface of the shell.

Abstract: A shoe sole of elastomeric material is formed with at least one pressurized gas cell at least one wall of which is defined by a layer in which a substantially inextensible reinforcement is embedded to prevent bulging. The cell envelope can be formed by rotational casting of a liquid material within a cavity of a wear layer to simultaneously penetrate the reinforcing layer.

Abstract: A flat composite board or panel for covering the vertical walls of rooms, which consists of a core (3) of synthetic foam produced in situ, an outer layer (2) having a decorative front surface (20) and a rear surface (21) to which the foam adheres, a synthetic layer (4) which adheres to the foam (3) by its front surface (41) and the rear surface (42) of which is covered with a web of fibres, the decorative front surface (20) of the board and its edges (12, 12') being covered with a sealed protective thermoplastic film (1) cooperating with the front surface (41) of the inner layer (4) to which it is secured at its ends (10) so as to form a sheath which limits the expansion of the foam and designed to be removed after the board has been fitted in position.

Abstract: An article comprising a generally axially extending outer, tubular member, a plurality of generally axially extending cylindrical members, and a heat expandable foam sealing member. The outer tubular member has at least one opening and occupies a predetermined volume. Each of the cylindrical members is received by outer tubular member in an axially extending, parallel fashion such that the cylindrical members occupy a volume that is less than the volume of the outer tubular member. The sealing member, capable of sealing the opening of outer tubular member, occupies a volume that is generally equal to the difference between the volume of the outer tubular member and the volume of the cylindrical members.

Abstract: A racket frame is formed from an elongate element produced by extrusion of a mixture of a thermoplastic material and carbon fibres. The element is bent while hot to form the racket head and has arms which are joined together by throat pieces, thereby forming the racket shaft. The throat pieces are formed by injection moulding. The elongate element preferably has at least one cavity extending along its length, the cavity being filled with foamed material of a density different from that of the elongate element so that the racket can have the desired weight. Preferably ropes of carbon fibres are included in the elongate element extending along its length. The aligned fibres give strength to the frame. In production of the frame the thermoplastic material may be extruded, cooled, have holes for strings formed in it, and then bent to shape or may be bent to shape immediately upon extrusion.

Abstract: An archery target comprising a foamed plastic core and a cover bonded directly to the core by the material of the core with the cover serving to retain the core in place when penetrated by arrows.

Abstract: Pipelines for transporting sewage, water, slurries, liquid and gaseous hydrocarbons, and like materials are interlined with a composite tubular lining having an inner skin layer and a foamed layer contiguous with the inner skin layer. The foamed layer is either contiguous also, along its opposite surface, with the inner wall of the pipe or may be spaced therefrom by an outer skin layer of the composite lining. The lining may be applied either before the pipeline is placed into service or afterward, whether in situ or removed for maintenance or repair. For application in situ the lining is preferably more flexible than will suffice for insertion into new pipes.

Abstract: A tool for use in a latex dip process for producing a latex skin in a given configuration, the tool being formed by producing an electro-formed female mold from a sculpture of the desired configuration, casting a vinyl skin from the electro-formed female mold, removing the vinyl skin to expose a hollow interior, and stuffing the vinyl skin with a composition of materials, having the characteristics of providing rigidity to the vinyl skin and approximately zero buoyancy in a latex bath.

Abstract: A method of manufacturing a foam insulated water heater of the type having an inner tank, a layer of insulating foam material surrounding the inner tank and an outer protective shell includes, in one embodiment, the steps of (1) forming a flexible, expandable bag in a configuration which may be placed between the tank and shell, (2) attaching the flexible bag between the tank and shell, (3) filling the bag with a foam material which expands, and (4) continuing to fill the bag so that foam material expands through relief openings in the bag to fill the remainder of the space between the tank and the shell.

Abstract: A body panel joint finishing method to produce a finished body panel joint by molding a bead directly to a vehicle body in a single operation without any need for secondary processing to remove excess materials. The method utilizes a foamable plastic as the bead forming material to provide greatly improved sealing property for moisture prevention in the gaps of the sheet metal body panel joints.

Abstract: A reticulated hydrophilic foam substrate and bonded active surface particle powder composite filter material is generated by foam polymerization of a prepolymer phase with an aqueous phase. The reticulated hydrophilic foam substrate is characterized by relatively low pressure drop and low resistance to flow through the foam substrate. The prepolymer phase is a hydrophilic polyurethane prepolymer receptive to the aqueous phase for foam polymerization upon mixing with the aqueous phase. The aqueous phase in turn is a pourable and flowable slurry mixture of water, active surface particle powder, and surfactant wetting agent. The aqueous phase includes sufficient water or other evaporable liquid to provide a protective liquid layer or coating over the active surfaces of the powder particles.

Abstract: A method of sealing cavities open on one side, preferably cavities of electrical equipment housings fitted with various components. A measured quantity of an encapsulant, preferably polyurethane foam, is inserted into the cavity. Thereafter the opening is covered by a permeable, absorbent fabric, preferably of polypropylene, which is covered first by an elastic and then a rigid layer. After hardening, the fabric is removed from the surface of the encapsulant.

Abstract: The foaming system, in particular for foaming refrigerator furniture or cabinets, comprises a first path for the translation of first means for independently carrying furniture pieces, possible means for preheating said furniture pieces, an operating station for handling masks, a second path for the translation of second means for independently carrying or displacing mask members and at least a stocking region for stocking the masks and the related furniture piece contained therein.

Abstract: A one-piece, hollow, moulded head for a golf-club of the "wood" or "driver" type is made by injecting a thermoplastics material around a fusible core having a melting-point below the injection temperature, allowing the injected material to set and melting out the core.One or more holes are provided, the holes extending completely through the core, so that the injected material fills each hole and sets therein to provide corresponding internal "struts" in the moulding.The injected material may be, e.g., a polyamide, a polycarbonate, a poly(phenylene oxide), an acetal resin or an ABS resin. The material may be reinforced with up to 50% by weight of glass and/or carbon fibres.The moulded head may optionally be filled with a polyurethane foam.The finished moulding may have the conventional face-pieces and/or sole-plates attached thereto.

Abstract: There is disclosed a method for fabricating a passive solar water heater having a heat absorber and storage tank within an insulative housing. The housing is formed in a mold as a unitary structure having an exterior shell and a curved insulative interior covered with a reflective inner surface. The tank rests in a trough in the housing and is secured by a mounting which prevents heat conduction to the environment. The shell material may be fiberglass and the insulative material may be expanded polymeric material.

Abstract: In order to facilitate the release of polyurethane from a steel or aluminium mould, the metal surface is provided with a mono-layer of an alkylmercaptan. A silver layer may be provided between the mould metal and the alkylmercaptan monolayer.The invention can be advantageously used for manufacturing a luminaire for a tubular discharge lamp.

Abstract: A method and apparatus for producing a molded article comprising covering at least a portion of the mold wall with a thin smooth surfaced soft lining as an integral permanent lower part of the mold cavity, thereafter loading a preformed grained vinyl shell against at least a portion of the soft lining; closing the mold and injecting a reactive plastic formulation into the mold such that the reactive plastic material forms a rigid backing layer that is strongly bonded to the vinyl shell without distorting the vinyl.

Abstract: A process for forming cloth-covered cushion articles. A mold is provided having the shape of the desired cushion article. In one form, a cloth covering is drawn into the mold. Foamable material is poured into the mold and cured to form the cushion article. The covered, cured article is removed from the mold and heated to at least the heat-fixable fiber set temperature of the cloth, as the cured foam acts as a male mold to hold the cloth in contour during heat setting. In another form, the foam is poured directly into the mold and cured. The cloth covering then is placed over the cured cushion and set.

Abstract: A composite sandwich formed by enclosing a central resilient layer of a soft compressible material between two plate-shaped parts of foamable synthetic material and inserting the assembly into a cavity formed from two shells of prefabricated sheet metal. The resultant composite is subjected to a heat treatment for about 10 minutes at about 200.degree. C. so that the foamable material expands to fill the cavity.

Abstract: A process for fabricating a closed, generally flat plastic object such as a surfboard, in one embodiment comprises the steps of:(a) providing a disassemblable mold having at least four parts comprising a bottom part, a top part and a pair of side rail parts, the interior surface of said mold having the desired shape of the exterior surface of said object;disassembling said mold and applying a clear gel coat to the interior surface of each said mold part;(c) applying laminations of a resin and reinforcing material mixture to each of said mold parts;(d) applying a layer of toluene diisocyanate to at least said top and bottom parts;(e) subjecting said top and bottom parts to a vacuum until said layers of toluene diisocyanate are each firmly adhered to the respective laminations of said mixture;(f) affixing the side rail parts to the bottom part forming a cavity therebetween;(g) coating the interior of the cavity with a resin and reinforcing material mixture;(h) allowing the resin mixture to become structurally s

Abstract: The molded shell of an article, while still warm from being molded, and while remaining within the mold or fixture in which it has been created, for instance by blow-molding of a parison of polyolefin plastic material into contact with the mold walls, is filled with a fluid, settable foaming plastic material, for instance polyurethane. This may be done by injecting the foaming mixture directly into the cavity of the shell. In this manner time, labor and materials are saved, and the resulting product is characterized by better adhesion of the foamed core to the internal wall surface of the shell.

Abstract: A cushion article, such as a seat cushion or the like, for snapping in place onto an appropriate seat support without additional attaching means. The seat cushion has a foam body with a snap-ring member molded integral with a peripheral portion of the body, the snap-ring member providing means for snapping the seat cushion over the seat support. A process and a mold assembly are disclosed for molding the seat cushion, utilizing the snap-ring member as an integral part of the process and mold assembly to evacuate entrapped air from the mold cavity.

Abstract: A body of polymeric material, comprising a core--e.g. of foam plastic--surrounded by a skin of greater density, includes a filler of metallic or other electrically conductive particles distributed throughout the core or at least in an intermediate layer separating an inner part of the core from the skin. The filler particles, preferably consisting of iron or aluminum, are injected together with all or part of the core material during the molding of the body.

Abstract: A portable fire resistant case 10 is made with a molded, double-walled resin body 11 and cover 12 hinged and locked together and filled with insulation in the spaces between the double walls. Spring latches 30 mounted on body 11 engage interlock surfaces 33 on cover 12 to hold cover 12 to body 11 independently of the hinge and are assisted in this by a lock element 27 engaging and holding projections on the inside of body 11. Body 11 and cover 12 are formed with molded filling projections 19 and 20 forming passageways into cavities 11c and 12c that are filled with insulation through filling projections 19 and 20. Projections 19 and 20 and overfilled insulation material that they contain are cut away after the insulation has set to leave insulation stubs 23 and 24 over which escutcheons 25 and 26 are mounted on the lock side of case 10.

Abstract: An artificial fishing lure which includes a pair of hooks normally disposed within a retracted position within the lure's body and movable therefrom to a position outwardly of the lure's body in response to a predetermined amount of tension being applied to a fishing line leading from the lure. For actuating said hooks, the present lure provides a flexible molded plastic bow assembly set within said lure's body and operatively interconnected between said fishing line and said hooks.

Abstract: A method and a mold for fabricating an aerodynamic airframe structure or the like. The method using foam material introduced into the mold having split halves. The mold constructed for receiving a prefabricated stiffener skin. The mold acts as a backup restraint for the airframe structure or any other part being produced. The foam injected into the cavity adheres to the stiffener skin thereby forming an elastic foundation of continuous support for the stiffening element.

Abstract: A process for preparing plastic articles having an outer rigid shell and an inner polystyrene foamed core, whereby pre-expanded polystyrene beads are foamed and fused inside a hollow thermoplastic shell, comprising, coating the inside of the shell prior to introducing the polystrene beads into the hollow shell, with a thermoplastic bonding layer.

Abstract: A continuous molding machine (10) for forming two chains (55) of soil plugs (50) for use in germinating seeds or otherwise growing plants. A continuous sheet of paper (22) is corrugated to conform to a series of mold elements (14) and a reaction mixture (32) of polymerizing agent and soil slurry is added over the paper to conform to the mold element shape. Another sheet of paper (38) is added over the top of the mixture (32) and the entire assembly is then passed under a series of pressure belts (42, 44, 46) during which time the mixture (32) is cured. The chain of soil plugs (50) which emerges from the pressure belts (42, 44, 46) is encased on both sides by paper (22, 38) and may be cut to provide a pair of separate soil plug chains (55).

Abstract: A method of manufacturing rigid frame building elements filled with hard foam plastic, said method comprising the use of prefabricated, rigid, dimensionally stable, hollow skeleton frames, the hollow interior spaces of said skeleton frames are foamed and filled with closed cell hard foam plastic serving as heat insulation, and the elements are subjected in a press to compression pressure which overrules the foaming pressured exerted on the frame of an element from inside. For continuous-action manufacture, the used press is a (known as such on the basis of size presses) continuous-action press machine whose lower frame is equipped with lower conveyor means (4) and upper frame with upper conveyor means (5), said conveyor means confining between themselves a conveying gap, in which the passing elements are maintained subjected to compression pressure by means of pressure members (7) carried by said conveyor means.

Abstract: A geodesic dome structure is described, i.e., a structure having a mathematically-derived surface. This new dome structure is formed of a single, one-piece layer of synthetic material and provides a one-piece, seamless screen to permit the viewing of a scene in a vehicle simulator in order to achieve a maximum of realism matching substantially real world conditions. One form of the structure for this geodesic dome is described with the single, one-piece layer of synthetic material bonded to a generally dome-shaped geodetic structure in order to provide sufficient strength for a free-standing structure. However, another form of the geodesic dome is described with the synthetic material formed of sufficient thickness to be strong enough to provide a free-standing structure, and the synthetic material may even be reinforced if desired.

Abstract: A method for producing a reinforced composite racket frame having an outer shell made of a fiber reinforced thermosetting plastic material and a foam core comprising the steps of: (a) placing an open-ended tubular shell of fiber reinforced thermosetting plastic material in a racket frame mold with two valve members respectively provided at an outlet and an inlet of the mold; (b) heating the mold to a first predetermined temperature for curing the tubular shell; (c) causing one of the valve members to be open and the other valve to be closed; (d) applying compressed air through the open valve to force the shell into intimate contact with an inner surface of the mold, the shell thereby assuming the shape of the mold; (e) cooling the mold to a second predetermined temperature at which the tubular shell becomes set to the mold shape; (f) opening the closed valve; (g) introducing a predetermined amount of a foamable material through at least one of the valves and into the shell; and (h) closing both of the valve m

Abstract: An improved method is described for molding an article having a core of foam and a surface reinforced by fiberglass cloth or the like, which enables more rapid setup for molding and which creates a stronger and more uniform article. The method includes laying several layers of dry tissure paper on the walls of the mold to form a first layer, laying dry fiberglass cloth over the first layer to create a second layer, and laying a sheet of dry tissue paper over the second layer to form a third layer. Foamable plastic is poured in the mold over the three layers and the mold is closed. As the plastic foams and expands, it first presses against the third layer to press it and the underlying first and second layers firmly against the mold walls to thereby position them evenly at the outer portion of the mold cavity. The foam material then penetrates the tissue paper of the third layer, the openings of the cloth of the second layer, and some of the layers of tissue paper of the first layer, before finally hardening.

Abstract: A mold assembly for molding a cushion article, such as a seat cushion or the like, for snapping in place onto an appropriate seat support without additional attaching means. The seat cushion has a foam body with a snap-ring member molded integral with a peripheral portion of the body, the snap-ring member providing means for snapping the seat cushion over the seat support. A mold assembly is disclosed for molding the seat cushion, utilizing the snap-ring member as an integral part of the process, and a mold assembly to evacuate entrapped air from the mold cavity.

Abstract: An apparatus is described for use in a urethane foam molding process to make a molded packing that is employed in the packaging of an article. A generally air tight housing is placed in cooperative relationship with a box in whose chamber the molded packing is to be made with one housing port located for air flow communication with the chamber and another housing port being located for air flow communication with ambient air. A pair of motor driven air blowers are mounted inside the housing with each air blower operatively positioned at a housing port. When one air blower is energized it causes the evacuation of air from the chamber of the box through one port to draw and hold a polyethylene sheet into the cavities of the chamber and of a mold form located therein. The air is exhausted past the other air blower and port. When the other air blower is energized, air flow through the ports is reversed so as to blow air into the box chamber for the release of the molded packing.

Abstract: Insulated pipeline components are produced by positioning a steel pipe in the cavity of a casting mold with the pipe ends protruding therefrom. The dimensions of the cavity are greater than those of the inner pipe, and in the space between the inner pipe and the contact surfaces of the mold cavity a plastic powder is introduced, the powder being melted by heating of the mold. The mold is then rotated in a manner well known in rotational molding technique so that centrifugal force drives the molten plastic material against the contact surfaces of the mold cavity to form a plastic jacket; and after the mold has cooled the component is removed and expandable plastic material is supplied to the space between the inner pipe and the plastic jacket and is foamed. The resulting component has an exactly centered inner pipe, lacks conventional joints and can be produced at relatively low cost in a manner complying with industrial safety requirements.

Abstract: Polyisocyanate addition products are made by reacting a polysiloxane having isocyanate reactive end groups, excess polyisocyanate and a compound selected from the group consisting of aliphatic alcohols, primary aliphatic amines, secondary aliphatic amines and mixtures thereof having a molecular weight of from 75 to 5000 and at least one tertiary amino group and/or oxyalkylene unit. In a preferred embodiment, the polysiloxane is reacted with excess polyisocyanate and the reaction product is subsequently reacted with the alcohol and/or amine. The addition products of this invention are particularly useful as mold release agents in the production of molded lacquer coated plastics by the "in-mold coating process.

Abstract: A polyolefin composition having improved adhesion to foamable plastic substrates, comprising an intimate mixture of about 20% to about 99.5% by weight of a first stabilized polyolefin powder and from about 0.5% to about 80% by weight of a second at most slightly stabilized polyolefin powder, said second powder having a crystalline melting point which is at least 1.degree. higher than that of said first powder and wherein said second powder has the ability to be oxidized under process conditions.

Abstract: This invention relates to a method of making a foam-containing structure which includes placing and suitably retaining a respective first shaped sheet in each of first and second complementary parts of an open mould. Each sheet includes at least one layer of fibrous material. A further respective shaped sheet is placed and suitably retained upon each first sheet. Each said further sheet comprises a layer of fibrous material and an impervious membrane adhering thereto. When the two mould parts are closed together a foamable material is introduced into a cavity formed between the sheets and is then caused to expand, whereupon each membrane is caused to adhere to its adjacent first sheet but prevents penetration of the expanding material into that sheet.

Abstract: A racket structure to be used in a tennis and the like racket and a method for producing it, where the handle section and the head frame section are made of a one-piece composite member including an inner light weight soft plastic core member having a central prestressed multifilament cord member and a glass fibers reinforced hard plastic, outer surrounding layer, anchored on said core member within the head frame section, said surrounding layer being covered on opposite faces with respective resilient flat cover members which also sheath part of the height of said head frame section on the inside face, facing the netting, defining the striking surface stretched in the oval space defined by the head frame section of the racket.

Abstract: A rotational molding process for manufacturing objects having a foamed plastic substrate adhered to an outer polyolefin coating layer, and having improved adhesion therebetween comprising the combination of steps of: preparing a first outer coating layer of a stabilized polyolefin; forming a second inner layer of an at most slightly stabilized polyolefin contiguous with and on the interior surface of said first outer layer; and thereafter introducing a foamable plastic material onto the interior surface of said second layer and foaming said plastic material thereagainst thereby the foamed plastic is bonded to said second interior surface.

Abstract: A flexible molded foam comprises a surface layer of elastic thin film, an intermediate reinforcing layer of elastic film and a core layer. The surface layer comprises a linear polymer, the intermediate reinforcing layer comprises a three-dimensionally crosslinked polyurethane and the core layer is composed of a semi-rigid polyurethane foam. These elements are integrally molded in a desirable shape.

Abstract: A flowable slidifyable mass is applied onto the inner surface of a hull made of an elastomeric material and corresponding to the human skin section. This flowable mass is let to solidify into a shell-like body. Thereafter the shell-like body is cut and machined such to produce an article corresponding in shape to a portion of the human skeleton. A molding mass which solidifies to a flexible body is injected into the void space defined by the elastomeric hull stretched over the skeleton portion such that a flexible negative form of the skeleton is produced. Thereafter the elastomeric hull, the negative form and the skeleton portion are separated from each other and the elastomeric hull stretched over the negative form only and a further molding mass is inserted into the void spaces defined by the elastomeric hull and the negative form such that an arbitrary number of skeleton portions can be produced.

Abstract: This relates to a closure utilizing a liner which is formed of plastisol or like material which puffs or expands upon curing after the liner has been applied. By providing the liner with a skirt portion and by increasing the radial thickness of a lower part of the liner skirt portion through a shaping of the skirt of the closure shell, the cured liner skirt portion will expand differentially and form, on the inner surface of the liner skirt portion, a bead which will snap over and lock beneath a bead on a container neck finish to lock the closure in a container sealing position. The closure may be removed and reapplied to reseal the container.

Abstract: A generally cylindrical thermally insulated ceramic container of imposing appearance suitable for use on dining tables comprises a double-wall ceramic container and insulation formed of a foaming resin of low thermal conductivity and contained in the inner cavity interposed between the two walls. The thermally insulated ceramic container is produced by preparing an inner green container wall and an outer green container wall one size larger, both of potter's dough, joining the two green container walls along the upper edges thereof with the walls radially opposed to each other across an intervening space (inner cavity), firing the resultant molded green double-wall container thereby producing a double-wall ceramic container, injecting an unfoamed or semi-foamed foaming resin into the inner cavity through a perforation bored in advance in the outer wall, and foaming the resin within the inner cavity.

Abstract: The method comprises a masking step of closing by masking tapes a gap formed between a roof rail member provided at the inner periphery of an existing roof panel and the roof panel, a linear joint portion between the roof rail and pillar inner panels, and holes provided for securing parts to the roof rail. The method also includes a step of arranging a wire harness assembly at predetermined position a lining skin member below the roof panel by securing and fitting welts provided around the periphery of the lining skin member to the roof panel. A foaming mold setting step is then carried out by mounting a foaming mold having the same shape as a final shape of the lining skin member from a compartment of the vehicle. A heating step is then performed to preheat the whole ceiling portion to a predetermined temperature and a foaming composition injecting step of injecting a foaming composition into a spaced formed between the roof panel and the lining skin member is carried out.

Abstract: A polyolefin composition having improved adhesion to foamable plastic substrates, comprising an intimate mixture of about 20% to about 99.5% by weight of a first stabilized polyolefin powder and from about 0.5% to about 80% by weight of a second at most slightly stabilized polyolefin powder, said second powder having a crystalline melting point which is at least 1.degree. higher than that of said first powder and wherein said second powder has the ability to be oxidized under process conditions.

Abstract: There is described a tennis racket the frame and shaft of which are formed by synthetic resin-impregnated fibres, such as glass and/or carbon fibres, aromatic polyamide or boron fibres, and the core both of the frame and the shaft is preferably filled with a synthetic foam with the purpose of determining the profile of those components formed by the fibres, in which inside the core is present at least in places in the frame and/or the shaft, at least one wood layer.