Abstract: A holder integrated type base board made of synthetic resin integrally molded with a plurality of holders for inserting LEDs on a front face side of a base board main body and a mold therefore. The mold includes a first mold for molding a back face side of the base board main body and a second mold opposed to the first mold for molding the front face side of the base body main body. In addition, the mold includes a holder molding cavity provided at the second mold which is constituted by an insert die capable of being inserted into and detached from the second mold main body. When it is necessary to correct a position of a portion of the holder in a trially fabricated base board, a position of an LED inserting hole in the base board can simply be corrected by drawing the insert die for molding the holder from the mold main body and interchanging the insert die with a new insert die. As such, an entire first mold does not have to be reproduced.

Abstract: Manufacture of moulded polyurethane or moulded polyurethane containing products, especially thermoplastic products, such as elastomers, flexible foam, and rigid foam using gas assisted injection moulding. Preferred polyurethane products are thermoplastic polyurethanes.

Abstract: The invention is an apparatus and method for producing a hybrid boron reinforced polymer matrix composition from powder pre-impregnated fiber tow bundles and a linear array of boron fibers. The boron fibers are applied onto the powder pre-impregnated fiber tow bundles and then are processed within a processing component having an impregnation bar assembly. After passing through variable-dimension forming nip-rollers, the powder pre-impregnated fiber tow bundles with the boron fibers become a hybrid boron reinforced polymer matrix composite tape. A driving mechanism pulls the powder pre-impregnated fiber tow bundles with boron fibers through the processing line of the apparatus and a take-up spool collects the formed hybrid boron-fiber reinforced polymer matrix composite tape.

Abstract: A process for producing molded pitch based foam is shown which provides a more uniform density gradient throughout the ultimate product. The process utilizes a pressure drop during processing in order to induce foaming. By inducing foaming through process depressurization, additional viscosity manipulation can be achieved as well as improved density gradient characteristics in the ultimate product.

Abstract: A releasing agent for embossing a thin film carried on a surface of a substrate with a mold having a high pattern density includes an alkyl silane.

Abstract: A method for manufacturing a pressed part from a soft magnetic composite material. A starting mixture is provided that includes an iron powder and an auxiliary pressing agent. The starting mixture is pressed to form a pressed part and annealed at temperatures between 380° C. and 450° C. in a mixture of an inert gas and oxygen that has an oxygen concentration between 1% and 10% by volume. A second embodiment of a method for manufacturing a pressed part from a soft magnetic composite material in which a starting mixture is provided that includes an iron powder and an auxiliary pressing agent. The starting mixture is pressed to form a pressed part, annealed, and then postformed and re-annealed.

Abstract: Polyethylene having a broad molecular weight distribution is extruded in pellet form using a pelletizing extruder having one or more zones essentially filled with the polyethylene and two or more zones partially filled with the polyethylene. The polyethylene is fed into the extruder at a temperature sufficient to melt the polyethylene, and a mixture of an inert gas and oxygen is fed into at least one partially filled zone of the extruder with the exception of the feed zone. The mixture contains about 1 to about 21% by volume oxygen based on the volume of the gas mixture.

Abstract: A process for producing atomized powder, such as a metal powder, using a recirculating atomization gas, such as helium, and the apparatus used for producing the atomized powder

Abstract: There is provided a manufacturing method of an optical device having a micro-asperity pattern that has various kinds of accurate three-dimensional shapes and is realized as thin films. A substrate is coated with a resin thin film made of a photosensitive resin, and the temperature of the resin thin film is controlled so as to be lower than the photosensitivity extinction temperature of the resin thin film. A micro-asperity pattern of a stamper is pressed against the resin thin film when the resin thin film is in a softened or melted state by pressurizing means, whereby a micro-asperity pattern is formed on the surface of the resin thin film.

Abstract: Thin, planar substrates are carried on a substrate carrier (20) through a polishing operation. The substrate carrier (20) is injection molded or modified-injection molded from a plastic material, and includes one or more receptacles for receiving the substrates to be carried through the polishing process. A drive force transmission arrangement is also included in the substrate carrier (20) through which the carrier may be driven in the polishing process. The substrate carrier (20) is relatively non-abrasive and composed of melt processable engineering polymers or blends. Non-abrasive fillers or reinforcing material may also be included in the plastic.

Abstract: The invention relates to a method for recycling polyethylene terephtalate (PET) flakes, characterized in that the flakes are extruded and granulated under vacuum, after which the granulate is aftercondensed in a solid phase under vacuum. Extrusion is preferably carried out in differentiated vent zones and aftercondensation of the solid phase is dependent on temperature, vacuum and time spent in a tumble dryer. Said dryer ensures the even and careful mixing and constant viscosity of the PET product. Said method is used in particular for making PET beverage bottles.

Abstract: Small particles of polymeric material are produced by expansion of a mixture of monomers and a propellant. The size and shape of the particles can be precisely tailored by materials selection and expansion conditions. Particles of 10 nanometers to 100 microns can be produced. If monomers exhibiting solid state reactivity are utilized, the particles thus formed can be polymerized at any time after formation. The particles produced by this method can be molecularly imprinted by incorporating a template into the particle prior to fully curing the particle, in a manner which allows selective extraction of the template from the cured particle after formation without deformation of the imprint site. A two step polymerization process allows the particles to be deposited on and adhered to a wide variety of substrates without additional agents.

Abstract: A process for manufacturing hollow handled toothbrushes is disclosed. The process includes; a) providing a toothbrush mold having a head portion, a base portion, a toothbrush cavity located between said head and end portions and having walls, an injection port for molten plastic, and a gas injection port, wherein the gas injection port is positioned in the end of the base portion of the mold so that gas is injected into the mold cavity substantially centrally thereof and in a direction parallel to the longitudinal axis of the mold; b) injecting a predetermined amount of a molten plastic into the mold cavity to partially fill the cavity; and c) injecting at least one gas through the gas injection port into the cavity to direct the molten plastic against the walls of the mold cavity.

Abstract: The invention disclosed provides integral multilayered polymers with variable interlayer gaps, and processes for their manufacture. The materials thus produced consist of many layers of a polymeric material, which may be a single polymer or a blend of compatible polymers, separated by discontinuous narrow gaps containing air and/or a blowing agent. The layer density can be controlled within a wide range, typically 10 to 2000 layers/mm, while the gap width between the layers can be controlled either to ≦100 nanometers (called nanolayered polymers) or ≧1 micrometer (called microlayered polymers), depending on the process. These layered materials are mechanically strong and have excellent thermal and electrical, and sound insulation properties. Two distinct mechanisms were developed for producing such materials.

Abstract: This invention is related to a method for encapsulating bond regions in electronic components comprising, for example, metallic bond regions, the method comprising the steps of exposing an electronic component having at least one bond region through a primary gas atmosphere comprising unstable or excited gaseous species, the gaseous species being substantially devoid of any electrical charges, the primary gas atmosphere having a pressure ranging from about 0.5×105 Pa to about 3.0×105 Pa, thereby forming a treated, non-encapulated electronic component, then encapsulating the electronic component.

Abstract: The present invention provides an injection molding method for providing a molded product with excellent transcription and an excellent gloss level. In this method, immediately after a resin is filled in a cavity (1), a carbon dioxide gas is injected or the skin layer is moved back to form a space (13) between the resin and the die surface (1), so that growth of the skin layer is hold down, and at the same time the carbon dioxide is dissolved in the skin layer for lowering the glass transition point of skin layer. Then the skin layer is again closely cohered to a surface of the die by increasing the resin pressure and cooling the molded product for solidifying behind the holding pressure. With this method, products with excellent transcription and with an excellent surface gloss level can be obtained.

Abstract: A method of manufacturing a bearing for use in an orthopaedic implant, comprises the steps of: providing a radiation source; positioning a bearing material at a distance away from the radiation source; installing a shield over at least a portion of the bearing material; irradiating the bearing material through the shield using the radiation source; and forming a bearing surface on the bearing material.

Abstract: A process for producing a thermoplastic resin pellet, which comprises melt-kneading a thermoplastic resin to obtain a thermoplastic resin pellet, wherein the thermoplastic resin comprising: (A) at least one thermoplastic resin selected from the group consisting of polyphenylene ether-based resins, polyacetal-based resins, polyamide-based resins, polystyrene-based resins, acrylic resins, polyester-based resins, polycarbonates, polyphenylene sulfides, polyetherimides, polyethersulfones, polysulfones, polyether (ether) ketones; and (B) a carbon dioxide gas contained in thermoplastic resin (A) in an amount of from 0.3 to 20.0 parts by weight per 100 parts by weight of thermoplastic resin (A).

Abstract: A process for production of polyimide molded bodies which comprises a step in which a polyimide resin powder obtained by polymerization and imidation of p-phenylenediamine with 3,3,4,4′-biphenyltetracarboxylic acid, its ester or its dianhydride and 2,3,3′, 4′-biphenyltetracarboxylic acid, its ester or its dianhydride is molded at a pressure of approximately 800-5,000 kgf/cm2, a step in which the pressurized body is subjected to calcination at about 450-550° C. under low pressure, a step in which the calcined molded body is vacuum encapsulated into a metal capsule, and a step in which the encapsulated molded body is isotropically subjected to hot compression at approximately 460-550° C. in an inert gas atmosphere such as argon. The polyimide molded bodies obtained thereby have a density in the range of 1.44-1.38 g/cm3.

Abstract: Molded products may be made by a process comprising preparing a structure comprising a block copolymer or a graft copolymer having two or more phases, wherein each phase is comprised of polymer chains, decomposing the polymer chains of at least one phase of the structure, and cleaning the structure with a supercritical fluid or a sub-critical fluid, thereby removing the decomposed polymer chains from the structure. Molded products made by this method have very low levels of residual solvents, can be manufactured at a relatively low temperature in a short period of time without using large amounts of organic solvents, and without discharging large amounts of liquid waste.

Abstract: According to this invention, there is provided a molding method and apparatus which increase the gas permeation speed in obtaining a foamed resin molded product by letting a gas permeate a molten resin material.

Abstract: A carbon-carbon composite material is made by providing an open-celled carbon foam preform, and densifying the preform with carbonaceous material. The open-celled carbon foam preform may be oxygen stabilized prior to carbonization, and the foam preform densified by CVD, HIP, PIC, VPI, pitch and resin injection, or any combination thereof. The carbon carbon composite material can be heat treated to provide thermal management materials, structural materials, or a friction material for use in a brake or clutch mechanism.

Abstract: A method for molding a thermoplastic resin by filling a molten thermoplastic resin into a mold which comprises carrying out the molding of the resin while reducing the solidification temperature of the resin surface which contacts with the mold during the step of filling the resin. According to this molding method, the state of the mold surface can be faithfully transferred to molded articles.

Abstract: A method is used to make a vulcanized elastomer capable of combining with Polyurethane to form a product without the use of an adhesive. The method includes the formation of the mixture of an vulcanizable elastomer. The mixture is stabilized in a nitrogen-containing chamber before the mixture is vulcanized. The vulcanized elastomer is formed in a molding tool and is subsequently degreased with a liquid containing a non-ionic interfacial agent. The degreased elastomer is dried by baking before being coated with the acetoacetate solution containing chloro cyanuric acid. The coated elastomer is dried again by baking before being stabilized in a dustproof environment for 48 hours. Upon completion of the dustproof stabilization, the elastomer is ready for combining with Polyurethane without the help of an adhesive.

Abstract: A process for producing an article of resin made from at least about 50% by weight of methyl methacrylate is provided, which comprises a step of melt-processing the resin with an extruder, wherein an oxygen concentration of a gaseous phase in a resin feed zone of the extruder falls within a range of from about 0.7% by volume to about 10% by volume. The article is excellent in curbing the coloring in melt processing.

Abstract: A method for molding a thermoplastic resin by filling a molten thermoplastic resin into a mold which comprises carrying out the molding of the resin while reducing the solidification temperature of the resin surface which contacts with the mold during the step of filling the resin. According to this molding method, the state of the mold surface can be faithfully transferred to molded articles.

Abstract: A treatment method for the internal surface of a moulded polyethylene plastics material container such as a drum, comprising the steps of: introducing an ionisable gas, such as argon, into the container; generating a plasma of the introduced gas by applying electric field of sufficient strength to the container and introduced gas, so as to cause an interaction with the internal surface of the container; coating the internal surface of the container with a curable epoxy-based first polymeric composition; and then curing the polymeric composition to form a coating on the internal surfaces of the container. A second coating, preferably with electrical conductive properties, may be applied and cured over the first coating. Conductive properties may provided by including conductive particles such as antimony doped tin dioxide, graphite or metal powders, in the second composition.

Abstract: Stretch blow molded containers are made from a preform made of a plastic material suitable for stretch blow molding such as, e.g., PET. The preform is heated to a temperature suitable for stretch blow molding and is introduced into a mold. An explosive gas mixture is introduced into the preform with a stretching pressure and the preform is axially stretched with the help of a stretching rod. After stretching, the explosive gas mixture is ignited, the explosion creating a blowing pressure which presses the wall of the preform against the inner wall of the mold so as to impart to the container its definite form. Due to the temperature shock generated by the explosion, the inner surface of the container is simultaneously sterilized.

Abstract: A method of continuously fabricating a lens excellent in various optical characteristics and having no nonuniformity in the characteristics over a total of the lens and a lens fabricated by the method. A first step for forming thiourethane prepolymer and a second step for making thiourethane prepolymer react with at least one urethane forming monomer are carried out in an extruder or in a reactor having an extruding device at a succeeding step, extruded thermoplastic thiourethane-urethane copolymer for optical use is elongated in a sheet-like shape, a lens precursor is formed by punching out the copolymer elongated in a sheet-like shape and the lens precursor is pressed such that a predetermined curved face is provided at least on one face of the lens precursor.

Abstract: This invention is directed to a method and system for using laminar barrier inerting techniques to shroud a selected area in an open space covering the polymeric film outlet and/or raw material inlet with inert gas.

Abstract: A method of slip casting wherein reduced pressure is applied to the mold during casting by virtue of a network of piping extending through the mold. The mold has an impermeable outer coating. Heat may also be applied to the mold during casting, by for example a heated fluid passing through piping located in the walls of the mold.

Abstract: A method for manufacturing artificial stone having a curved surface or a deformed shape including the steps of heating a plate-like artificial stone forming body, whose surface has previously been polished or roughened, to a temperature ranging from 120° C. to 200° C. under a pressurized atmosphere equal to or higher than 3 atms so as to soften and deform it to a predetermined curved surface or deformed shape and cooling it to a temperature not higher than 90° C.

Abstract: Prophylactic devices are made in an inert atmosphere by cooling mandrels on which the devices are to be deposited, dipping the mandrels into a polymeric material in a solvent/carrier and a mold release agent, rotating the mandrels during and after the dipping, and evaporating the solvent after dipping. The apparatus includes an air lock between a section in which these functions are performed and a section located in an air atmosphere for removing the devices from the mandrels, followed by cleaning the mandrels for use in a subsequent production run for making devices.

Abstract: Devolatilization of molten polymer is carried out using a vertical static mixer which opens directly into a flash tank. Expansion of a stripping agent injected at an inlet of the static mixer occurs in the static mixer and the continued shearing causes disengagement of the vapor from the polymer, so that expansion is complete before the polymer enters the flash tank and stripper and volatiles are removed by a pump and condenser arrangement which holds the flash tank at a reduced pressure. Polymer outlets are in the floor of the flash tank and have metering pumps at their bottom end.

Abstract: A method of treating contact lenses made from polymerizable materials by providing supercritical fluids to the lenses.

Abstract: A method for forging, or hot working bulk ceramics, including high temperature superconductors and other sensitive materials, under precisely controlled conditions of pressure, temperature, atmospheric composition, and strain rate. A capsule with massive end plates and with an independent gas supply is located in a modified hot isostatic press (HIP), designed to operate at pressures of up to 200 MPa and at temperatures of up to 1000 C. Essentially uniaxial deformation of a pre-compacted disc with forces of up to 500,000 Newtons (50 tons), and over time scales from seconds to hours can be achieved by separately controlling the pressure in the capsule from that of its surroundings. The separate gas supply to the capsule can also maintain a specified gaseous atmosphere around the disc, up to the operating pressure of the equipment. The apparatus can be designed to tolerate oxygen concentrations of up to 20%.

Abstract: To prevent socalled fish eyes or to reduce the number of fish eyes per unit of area in plastic films, manufactured according to the casting process or according to the blown film process, the number of fish eyes per unit of area is measured in the tubular film, which is cast or blown or collapsed. When the measurement reveals a number of fish eyes per unit of area that exceed a specified value, nitrogen or antioxidants are blown or put into the hopper until the number of fish eyes per unit of area falls below a critical number.

Abstract: A bypass conduit having a desired hollow internal geometry for defining a bounded blood flow path from an open first end positioned in a heart chamber and an open second end connected to a lumen of a coronary vessel is made by forming a master having an external surface with an external geometry complementary to the desired internal geometry of the conduit. The external surface of the master is coated with pyrolytic carbon to define a pyrolytic carbon conduit of pyrolytic carbon bonded to the external surface of the master and with the pyrolytic carbon having an internal surface with a conduit geometry complementary to the external geometry of the master. The master is removed from the pyrolytic carbon conduit.

Abstract: A method for injection-molding a cross-linked, foamed composition including the introduction of an inert gas into a mold chamber of a preheated mold to evacuate air and oxygen from the mold chamber. A mixture of a resin, a cross-linking agent and a chemical blowing agent are introduced into the mold chamber after the inert gas has evacuated air and oxygen from the mold chamber. The inert gas is evacuated from the mold chamber while the mixture substantially fills the mold chamber. The mixture is heated within the mold chamber to a temperature sufficient to thermally decompose the chemical blowing agent. The temperature of the mixture is maintained within the mold chamber until the resin substantially forms a cross-linked composition. The mold is opened and the cross-linked composition foams to produce a finished product that is free of oxidation.

Abstract: A method of treating contact lenses made from polymerizable materials by providing supercritical fluids to the lenses.

Abstract: A process for producing a carbon foam heat sink is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Abstract: The process obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications.

Abstract: The present invention provides a carbon composite material which is a molded material comprising (a) an expanded graphite powder and (b) a thermoplastic resin or a thermosetting resin or a fired product of the thermosetting resin, and the expanded graphite powder (a) being dispersed in the component (b), wherein the expanded graphite powder has an average particle diameter of 5-12 .mu.m and at least 80% of the total particles of the expanded graphite powder have particle diameters of 0.1-20 .mu.m; and a process for producing a carbon composite material, which comprises mixing and dispersing a thermoplastic or thermosetting resin and the expanded graphite powder as mentioned above, and then pressure-molding the resulting mixture at room temperature to 400.degree. C., or a process for producing a carbon composite material, which comprises mixing and dispersing a thermosetting resin and the expanded graphite powder as mentioned above, pressure-molding the resulting mixture at room temperature to 400.degree. C.

Abstract: An apparatus and a method for molding of polyester articles having low acetaldehyde content directly from a melt without intermediate solidification of the molten polyester. A melt to mold process is used wherein an acetaldehyde stripping agent is mixed into a polyester melt before devolatilization in a flash tank. The devolatilized polyester is pumped out of the flash tank and injected into a mold, thus forming a shaped article. The apparatus may include one or more flash tanks in one devolatilization line, or multiple devolatilization lines may be used stemming from one main polymerization reactor. The final shaped article should contain less than 10 ppm of acetaldehyde.

Abstract: A method for manufacturing a sheet molded part by polymerization of lactams in a sheet mold includes the steps of placing a fiber composite material into a sheet mold having large plane surfaces and fixedly positioning the fiber composite material in the sheet mold. Subsequently, the lactams are introduced into the sheet mold and the lactams are polymerized.

Abstract: Methods for producing plastic scintillating material employing either two major steps (tumble-mix) or a single major step (inline-coloring or inline-doping). Using the two step method, the polymer pellets are mixed with silicone oil, and the mixture is then tumble mixed with the dopants necessary to yield the proper response from the scintillator material. The mixture is then placed in a compounder and compounded in an inert gas atmosphere. The resultant scintillator material is then extruded and pelletized or formed. When only a single step is employed, the polymer pellets and dopants are metered into an inline-coloring extruding system. The mixture is then processed under a inert gas atmosphere, usually argon or nitrogen, to form plastic scintillator material in the form of either scintillator pellets, for subsequent processing, or as material in the direct formation of the final scintillator shape or form.

Abstract: A method of making an ophthalmic lens including the steps of: preparing a polymerizable composition comprising excessive oxygen content; contacting the polymerizable composition with a gas that is inert or substantially inert to the polymerizable composition, and deoxygenating or partially deoxygenating the polymerizable composition; conveying all or part of the polymerizable composition to an ophthalmic lens mold; polymerizing all or part of the polymerizable composition and obtaining a polymeric ophthalmic lens, and the lens produced by such process.

Abstract: The invention provides in improved proton exchange membrane for use in electrochemical cells having internal passages parallel to the membrane surface, an apparatus and process for making the membrane, membrane and electrode assemblies fabricated using the membrane, and the application of the membrane and electrode assemblies to a variety of devices, both electrochemical and otherwise. The passages in the membrane extend from one edge of the membrane to another and allow fluid flow through the membrane and give access directly to the membrane for purposes of hydration.

Abstract: An apparatus for forming a collagen fiber having microparticulates coated on the surface of the fiber and the method for forming the fiber are disclosed.

Abstract: The present invention provides a new and improved process of producing vehicle grille guards by gas-assisted injection molding and the grille guards produced thereby. The process includes injecting a plastic resin into a mold cavity in an amount less than the total volume of the mold cavity. An inert gas in then injected into a center portion of the cavity and a hollow gas channel extending throughout the center portion is formed, forcing the plastic resin to flow along an outer surface of the cavity.