Injection Molding Of Polyolefin-type Foam Patents (Class 264/DIG83)
  • Patent number: 6103175
    Abstract: The invention relates to a process for manufacturing injection moulded objects of thermoplastic material by injecting molten thermoplastic material into a mould from at least two distinct injection points whereas the flows of molten material from each injection point each fill part of the mould and flow together to fill the entire mould while still in molten state, wherein objects having a size of more than 80 cm along each of its three dimensional axes are produced by providing at least two distinct injection points at opposite sides of the mould. The invention also relates to injection moulding equipment for the manufacture of moulded objects of thermoplastic material, comprising at least two distinct injection points provided at opposite sides of a single mould assembly. The invention further also relates to threedimensional moulded objects of thermoplastic material having a size of more than 80 cm along each of its threedimensional axes.
    Type: Grant
    Filed: January 14, 1997
    Date of Patent: August 15, 2000
    Assignee: Innova Packaging Systems, N.V.
    Inventor: Michel Vandevelde
  • Patent number: 5684055
    Abstract: The present invention provides a method for the semi-continuous production of microcellular foam articles. In a preferred embodiment, a roll of polymer sheet is provided with a gas channelling means interleaved between the layers of polymer. The roll is exposed to a non-reacting gas at elevated pressure for a period of time sufficient to achieve a desired concentration of gas within the polymer. The saturated polymer sheet is then separated from the gas channelling means and bubble nucleation and growth is initiated by heating the polymer sheet. After foaming, bubble nucleation and growth is quenched by cooling the foamed polymer sheet.
    Type: Grant
    Filed: December 13, 1994
    Date of Patent: November 4, 1997
    Assignee: University of Washington
    Inventors: Vipin Kumar, Henry G. Schirmer
  • Patent number: 5489385
    Abstract: Drip chambers and expansion chambers for the transfer of blood are disclosed, including a housing, an entry port in the upper portion of the housing, an exit port in the lower portion of the housing, and at least one filter integral with either the upper or lower housing portions. Methods for manufacturing these chambers are also disclosed.
    Type: Grant
    Filed: February 14, 1994
    Date of Patent: February 6, 1996
    Assignee: Gambro Dialysatoren GmbH & Co. KG
    Inventors: Herbert Raabe, Gottfried Recktenwald
  • Patent number: 5424112
    Abstract: An injection molding of a synthetic resin having a foamed injection pressure transmission material remaining in an injection pressure transmission channel can be produced with lower clamping force and with greater dimensional accuracy. The molding preferably has the following characteristics:(1) a thick-walled section is substantially connected to a gate;(2) an injection pressure transmission channel is formed in the inside of the thick-walled section;(3) the injection pressure transmission channel is filled with the foamed injection pressure transmission material;(4) the injection pressure transmission material comprises a foamable low molecular weight polymer:(5) an amount of the injection pressure transmission material is 1/10 or less of that of the synthetic resin by volume;(6) a viscosity of the low molecular weight polymer is 1/50 or less that of the synthetic resin at injection, and 0.5 poise or more;(7) a ratio of (a viscosity of the low molecular weight polymer at 120.degree. C.)/(that at 220.degree.
    Type: Grant
    Filed: August 6, 1993
    Date of Patent: June 13, 1995
    Assignee: Asahi Kasei Kogyo Kabushiki Kaisha
    Inventors: Hiroshi Kataoka, Masanori Mawatachi
  • Patent number: 5182058
    Abstract: A method of making a foamed polymer article by injection molding, using a foaming agent that evolves minimal water and does not form byproducts which could pit or chalk the polymer surface. The foaming agent contains sodium borohydride in an amount from 0.01 weight percent of the polymer to be foamed, and a polyhydric alcohol such as six-carbon mannitor as an activator to react with the sodium borohydride and produce hydrogen gas. Boric acid can be included with the alcohol. the sodium borohydride is kept separated from the other reactive components such as by encapsulation until gas production is desired when the polymer is heated and molded.
    Type: Grant
    Filed: November 22, 1991
    Date of Patent: January 26, 1993
    Assignee: Quantum Chemical Corporation
    Inventors: Jawad H. Murib, Pradeep D. Damle
  • Patent number: 5140051
    Abstract: A method of making a foamed polymer article by injection molding, using a foaming agent that evolves minimal water and does not form byproducts which could pit or chalk the polymer surface. The foaming agent contains sodium borohydride in an amount from 0.01 weight percent of the polymer to be foamed, and a polyhydric alcohol such as six-carbon mannitol as an activator to react with the sodium borohydride and produce hydrogen gas. Boric acid can be included with the alcohol. The sodium borohydride is kept separated from the other reactive components such as by encapsulation until gas production is desired when the polymer is heated and molded.
    Type: Grant
    Filed: April 1, 1992
    Date of Patent: August 18, 1992
    Assignee: Quantum Chemical Corporation
    Inventors: Jawad H. Murib, Pradeep D. Damle
  • Patent number: 5128079
    Abstract: A method of making a foamed polymer article by injection molding, using a foaming agent that does not form byproducts which could pit or chalk the polymer surface. The foaming agent contains sodium borohydride in an amount from 0.01 to 5.0 weight percent of the polymer, and sodium dihydrogen phosphate as an activator to react with the sodium borohydride and produce hydrogen gas. The sodium borohydride and the sodium dihydrogen phosphate are kept separated from direct contact with each other, such as by encapsulating the components, until gas production is desired when the polymer is heated.
    Type: Grant
    Filed: December 22, 1991
    Date of Patent: July 7, 1992
    Assignee: Quantum Chemical Corporation
    Inventors: Pradeep D. Damle, Jawad H. Murib
  • Patent number: 4952365
    Abstract: A process for producing a foamable thermoplastic resin article having a relatively thin non-foamed outer shell with a smooth surface and a foamed core portion, which has excellent dimensional stability, by pressurizing a mold cavity under a pressure of gas less than the foaming pressure and not less than the surface smoothing pressure of the foamable resin and permitting the pressure of the gas simultaneously with completion of the injection to be communicated to an atmospheric pressure or lower.
    Type: Grant
    Filed: March 18, 1987
    Date of Patent: August 28, 1990
    Assignee: Asahi Kasei Kogyo Kabushiki Kaisha
    Inventors: Takehiro Shibuya, Takashi Nagahara, Susumu Imai
  • Patent number: 4919878
    Abstract: A process for the production of optionally foamed moldings having a compact surface by the reaction in closed molds of a mixture of(a) organic polyisocyanates,(b) compounds containing isocyanate-reactive groups and having a molecular weight of 62 to about 10,000 and(c) mold release agents based on salts of (i) saturated or unsaturated aliphatic or cycloaliphatic carboxylic acids or carboxylic acid mixtures containing (on a statistical average) at least 8 carbon atoms per molecule and (ii) tertiary amines,characterized in that the release agents (c) used are salts in which the amine component (ii) is based on tertiary monoamines or mixtures of tertiary monoamines corresponding to the following formula ##STR1## in which R.sub.1 represents a saturated or unsaturated aliphatic hydrocarbon radical containing at least 12 carbon atoms and R.sub.2 and R.sub.
    Type: Grant
    Filed: August 3, 1987
    Date of Patent: April 24, 1990
    Assignee: Bayer Aktiengesellschaft
    Inventors: Friedhelm Pilger, Richard Kopp, Otto Ganster
  • Patent number: 4897231
    Abstract: An anodized aluminum sheet is prepared by applying an aqueous polyurethane 40 percent dispersion coating with a threaded roller having 20-1/32 inch deep triangular threads per inch. The coating is heated by graduated heating from about 125 degrees F. to about 240 degrees F. for about 20 minutes until the material is set and non-tacky. Thereafter, without special storage or handling requirements, the coated side of the anodized aluminum is bonded in a mold under reaction injection molding pressure to a reaction injection molding material.
    Type: Grant
    Filed: February 13, 1989
    Date of Patent: January 30, 1990
    Assignee: Wellington Leisure Products, Inc.
    Inventors: Robert S. Scheurer, Kendal Hancock
  • Patent number: 4882107
    Abstract: A process which comprises (i) the generation of release surfaces by application to predetermined areas of a solid surface of a solution, suspension or dispersion of a release agent and a supercritical fluid that vaporizes from the release agent, (ii) the deposition of a mass onto the release surface containing the release agent, and (iii) the separation of the mass or a product derived from the mass from such surface covered by the release agent. Novel apparatus for carrying out the process are described.
    Type: Grant
    Filed: November 23, 1988
    Date of Patent: November 21, 1989
    Assignee: Union Carbide Chemicals and Plastics Company Inc.
    Inventors: Keith D. Cavender, Edmond J. Derderian, Eugene L. Jarrett, Kenneth A. Nielsen
  • Patent number: 4873032
    Abstract: A pour hole closure for use with an injection foam molding system including a mold assembly having a pour bushing leading to a reaction chamber. A cylinder having a slightly oversized plastic plug extending downwardly therefrom is normally positioned above the pour bushing in the mold assembly. The cylinder is pivotally movable away from its normal position against the force of resilient means. A pour head and nozzle assembly is adapted to move into engagement with the cylinder to move the latter while attaining a position wherein the nozzle is positioned above the pour bushing. The nozzle is lowered to engage the top edge of the pour bushing for injection of foam material into the reaction chamber.
    Type: Grant
    Filed: April 18, 1988
    Date of Patent: October 10, 1989
    Assignee: Davidson Textron Inc.
    Inventor: Webster Kohlhase
  • Patent number: 4843109
    Abstract: Shaped articles are provided containing a polymer which is capable of exhibiting anisotropy in the melt characterized in that the ratio of the stiffness in any two directions at right angles in the shaped article differs by at least 10%, and preferably by at least 50%, from the ratio in the same two directions for a control sample made from a melt consisting entirely of the polymer in anisotropic form.These may be obtained by a variety of methods including disturbing the normal flow pattern of flow into a mould by including obstacles to flow in the mould, disturbing the pattern of flow by foaming in the mould, by including fillers or by using polymers capable of existing as a bi-phase anisotropic and isotropic melt and forming shaped articles in which the two-phase disposition is retained.
    Type: Grant
    Filed: December 15, 1987
    Date of Patent: June 27, 1989
    Assignee: Imperial Chemical Industries PLC
    Inventors: Derrick S. Bailey, Frederic N. Cogswell, Brian P. Griffin
  • Patent number: 4839116
    Abstract: There is disclosed a one-piece short distance golf ball which is formed by foam molding a thermoplastic polymer and a filler. The resulting golf ball has a dense outer skin and a cellular core structure. The golf ball is approximately half the weight of and plays approximately half as far as a conventional golf ball, but its performance characteristics are otherwise comparable to a conventional golf ball. In addition a bramble surface pattern is provided on the ball to reduce the effects of wind on the ball's flight.
    Type: Grant
    Filed: October 24, 1985
    Date of Patent: June 13, 1989
    Assignee: MacGregor Golf Company
    Inventors: Troy L. Puckett, Lauro C. Cadorniga
  • Patent number: 4830793
    Abstract: The invention provides a method and apparatus for the high pressure injection of polyurethane foam into a hollow envelope using means of the type including a chamber for mixing the constituents of the polyurethane foam, a cylinder communicating with said chamber and open at both its ends, one of its ends opening into the orifice of the hollow envelope and the other end serving as inlet for a piston adapted for sliding in said cylinder and driving the polyurethane foam therefrom into said envelope, wherein said envelope is substantially vertical, its upper end opens into the orifice of the hollow envelope and is of a volume close to half that defined by the envelope and the movement of the piston in said cylinder is adjustable in synchronism with the cycle of the mixing head.
    Type: Grant
    Filed: July 17, 1984
    Date of Patent: May 16, 1989
    Assignee: Establissements Treves - Societe Anonyme Francaise
    Inventors: Claude Fermigier, Luc Fermigier
  • Patent number: 4824732
    Abstract: The invention provides a process and apparatus for producing an injection moulding of plastics material.
    Type: Grant
    Filed: April 29, 1986
    Date of Patent: April 25, 1989
    Assignee: Cinpres Limited
    Inventors: James W. Hendry, Geoffery D. Cahan
  • Patent number: 4806294
    Abstract: A method of making a foam injection molded article is disclosed wherein corrosion of the mold element is significantly reduced or substantially eliminated. The method comprises dispersing effective amounts of a primary chemical blowing agent of sodium borohydride and an activation system of sodium bicarbonate/citric acid mix into a polymer resin to form a mixture. The mixture is then heated whereby the activation system releases water and the sodium borohydride reacts with the water to produce hydrogen gas. The mixture is subsequently injected into a mold to obtain expansion of the polymer resin to form the foam article. The invention also comprehends a corresponding chemical blowing agent composition.
    Type: Grant
    Filed: June 15, 1988
    Date of Patent: February 21, 1989
    Assignee: Enron Chemical Company
    Inventors: Robert M. Lapierre, Nicholas J. Leonardi
  • Patent number: 4792576
    Abstract: The present invention is directed to a process for the production of polyurethane moldings by reacting a reaction mixture comprising(a) an organic polyisocyanate(b) a compatible polyol blend comprising(i) at least one polyether polyol having an hydroxyl functionality of from 2 to 8, and a molecular weight of from 350 to below 1800, and(ii) at least one hydroxyl functional organic material containing from 2 to 8 hydroxyl groups and having a molecular weight below 350, components (i) and (ii) being used in a weight ratio of component (b)(i) to (b)(ii) of from about 10:1 to about 1:10, and(iii) no more than 45% by weight based on the weight of component (b) of an active hydrogen containing compound having a molecular weight of 1800 or more,said reaction mixture being processed as a one-shot system by the RIM process at an isocyanate index of from about 70 to about 130.
    Type: Grant
    Filed: July 23, 1987
    Date of Patent: December 20, 1988
    Assignee: Mobay Corporation
    Inventor: Neil H. Nodelman
  • Patent number: 4783295
    Abstract: An improved process for producing a molded microcellular elastomer with a reduced number of voids from at least two liquid reactants and a gas, which process comprises introducing into at least one reactant a gas to form an admixture; passing the admixture through a static mixer at superatmospheric pressure; then immediately mixing the admixture with the other reactant at superatmospheric pressure to form a reaction mixture; introducing the reaction mixture into a mold in which the pressure is substantially below the superatmospheric pressures used above; and curing the reaction mixture in the mold to produce a molded microcellular elastomer with a reduced number of large voids.
    Type: Grant
    Filed: December 17, 1985
    Date of Patent: November 8, 1988
    Assignee: Union Carbide Corporation
    Inventors: James D. Kearns, Ronald J. Stapleton
  • Patent number: 4783296
    Abstract: A process for producing polyurethane foam articles is described, in which the article is produced in the conventional manner by foaming in a mould and a release agent is applied to the mould surface prior to filling with the foam-producing components. According to the invention, a solvent-free, aqueous release agent is used in combination with one or more alkali metal and/or ammonium salts of higher fatty acids and one or more higher alcohols and the combination is applied in the hot state, preferably at a temperature of at least 75.degree. C. to the mould surface. In addition, an additive is described, which is suitable for performing the process according to the invention and contains one or more alkali metal and/or ammonium salts of higher fatty acids, one or more higher alcohols and otherwise water.
    Type: Grant
    Filed: November 6, 1986
    Date of Patent: November 8, 1988
    Assignee: Teroson GmbH
    Inventors: Wolfgang Fischer, Thomas Hattich, William Krug, Gerhard Schuster
  • Patent number: 4783292
    Abstract: A method of forming a foamed plastic article, comprising the steps of: injecting pressurized gaseous bubbles into a stream of heated liquid plastic; feeding the heated liquid, with entrained gas bubbles, into a mold cavity without expanding the bubbles; slowly expanding the mold cavity to permit the gas bubbles to expand and thereby produce a foamed plastic article; controlling the temperature of the mold cavity surfaces so that the plastic material is in a viscous liquid state during at least the major part of the bubble expansion process; and cooling the mold cavity surfaces to a temperature less than the melt point of the plastic.
    Type: Grant
    Filed: June 15, 1987
    Date of Patent: November 8, 1988
    Inventor: Roy K. Rogers
  • Patent number: 4778659
    Abstract: In the invention, reaction raw-materials composed of a plurality of liquids are sequentially scraped with spiral grooves of one line or more provided in the peripheral face of the rotation shaft rotating within the cylinder wall with the discharge openings being formed therein. The reaction raw-materials are uniformly mixed within the grooves by shearing force or twist force through the rotation of the shaft. The reaction raw-material, if small amount, may be precisely mixed uniformly and is sequentially discharged after the mixing operation. This is suitable for reaction raw-materials which are short in the gelatin condition time from the mixing from the hardening. Some mixtures which are discarded without being used after the mixing may be reduced.
    Type: Grant
    Filed: July 22, 1986
    Date of Patent: October 18, 1988
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventor: Takao Inoue
  • Patent number: 4774040
    Abstract: There is provided a process for the manufacture of molded bodies of polyurethane integral foam, such as body parts for the automotive industry, in which the first step of the process, the polyol component is prepared and in the second step of the process the polyol component is reacted with the isocyanate component according to the reaction injection molding method. In the mold and/or after removal from the mold, the molded bodies are subjected to thermal aftertreatment within the framework of a third process step for thirty minutes to three hours at 120.degree. to 180.degree. C. Also, the polyol component may contain nucleating agents, so that the nucleated molded bodies may or may not need be thermally aftertreated.
    Type: Grant
    Filed: September 4, 1987
    Date of Patent: September 27, 1988
    Assignee: Phoenix Aktiengesellschaft
    Inventors: Thies Timm, Herbert Schaper, Reinhard Krassig
  • Patent number: 4769204
    Abstract: The reactive injection molding of a urethane-based resin composition according to the invention is performed by admixing the polyol compound as one of the reactants of the urethane-based resin with a specific organopolysiloxane as an internal mold release agent so that the molding process can be performed without application of an external mold release agent to the metal mold. The organopolysiloxane is characterized by two types of substituent groups bonded to the silicon atoms, of which the first type is --C.sub.x H.sub.2x OR', R' being a monovalent hydrocarbon group of 8 to 30 carbon atoms free from chain end unsaturation and x being 0-4, and the second type is --C.sub.y H.sub.2y (OC.sub.n H.sub.2n).sub.m OH, y being 1-4, n being 2-4 and m being 0-45.
    Type: Grant
    Filed: December 2, 1986
    Date of Patent: September 6, 1988
    Assignees: Shin-Etsu Chemical Co., Ltd., MD Kasei Limited
    Inventors: Toshio Oba, Kenichi Isobe, Shintaro Tachibana, Kazuo Shoji
  • Patent number: 4769397
    Abstract: A method of making a foam injection molded article is disclosed wherein corrosion of the mold element is significantly reduced or substantially eliminated. The method comprises dispersing effective amounts of a primary chemical blowing agent of sodium borohydride and an activation system of sodium bicarbonate/citric acid mix into a polymer resin to form a mixture. The mixture is then heated whereby the activation system releases water and the sodium borohydride reacts with the water to produce hydrogen gas. The mixture is subsequently injected into a mold to obtain expansion of the polymer resin to form the foam article. The invention also comprehends a corresponding chemical blowing agent composition.
    Type: Grant
    Filed: September 18, 1986
    Date of Patent: September 6, 1988
    Assignee: Enron Chemical Company
    Inventors: Robert M. Lapierre, Nicholas J. Leonardi
  • Patent number: 4767664
    Abstract: A process for preparing a polyurethane foam handle having a woodgrain finish is disclosed, which comprises injecting a composition comprising a polyol, a polyisocyanate, a crosslinking agent, a catalyst, a foam stabilizer and a blowing agent into a mold having a shape of a handle, blowing and curing the composition and applying a woodgrain finish coating on the formed handle. In this process, a polyol comprising 50 to 100 parts by weight of a polyether polyol having at least two OH groups in the molecule and having a molecular weight of 1,000 to 10,000 and 0 to 50 parts by weight of a polymer polyol having a hydroxyl number of 20 to 50, which is formed by graft-polymerizing a vinyl compound onto a polyether polyol, is used as the polyol, and 10 to 30 parts by weight of a polyol having 2 to 4 OH groups in the molecule and having a hydroxyl number of 800 to 2,000 is used as the crosslinking agent.
    Type: Grant
    Filed: May 27, 1986
    Date of Patent: August 30, 1988
    Assignee: Izumi Jidousha K.K.
    Inventor: Takeshi Oike
  • Patent number: 4766025
    Abstract: A composite molded article and a method of fabricating such an article is disclosed, which is especially well-suited for forming one-piece interior vehicle panels, by way of a single molding operation, wherein the one-piece interior panel can be easily installed as a unit within the vehicle. In the fabrication of the one-piece molded composite article, a deformable sheet material, such as vinyl, is positioned on a female molding surface and drawn into conformity with the female molding surface of the mold cavity, either with or without preheating or vacuum forming. The mold apparatus is closed and a first moldable material is introduced into the mold assembly, with certain predetermined portions thereof being blocked off. Subsequently, a second moldable material is introduced at least into the predetermined areas previously blocked off during the introduction of the first moldable material.
    Type: Grant
    Filed: September 25, 1986
    Date of Patent: August 23, 1988
    Assignee: Sheller Globe Corp.
    Inventors: John L. Sanok, Michael L. Piechura
  • Patent number: 4734230
    Abstract: A composite plastic product is formed by a process which includes formation of a preform of high strength plastic having openings formed therethrough which are covered by a film barrier that is formed during molding of the preform; and wherein the preform is configured to be placed as a unit in a foam station at which material is foamed onto the insert without escape to its backside.
    Type: Grant
    Filed: July 24, 1986
    Date of Patent: March 29, 1988
    Assignee: Ex-Cell-O Corporation
    Inventors: Richard D. Rhodes, Jr., Frank J. Preston
  • Patent number: 4729863
    Abstract: The present invention is directed to a process for the manufacture of molded parts having areas in the form of grids, grills or gratings, in which a fluid mass is introduced into the mold cavity of a molding tool conforming to the molded part and the cavity is filled by said fluid mass, characterized in that in the mold cavity, the zones provided for the apertures in the areas conforming to the said grids, grills or gratings of the molded part are first flooded by the mass and the mass is subsequently displaced from these zones, and to a molding tool to be used in such process.
    Type: Grant
    Filed: May 16, 1985
    Date of Patent: March 8, 1988
    Assignee: Bayer Aktiengesellschaft
    Inventors: Heinz Muller, Klaus Schulte, Lothar Klier
  • Patent number: 4725389
    Abstract: A method for foaming and sintering of foamable plastic employing a control method based on the detection of the softening time point during the sintering steam application in the sintering process step. The softening time point is detected by analysis of a change in the rising speed of the pressure or temperature, and the related pressure and temperature values are used for determining the maximum dismission temperature and pressure of the sintered product. The sintering time is determined in relation to the softening time point and the quality demanded. A feed back control to the prefoaming and drying process step is provided. A feed back control by means of a quality measurement at the sintered part to the sintering is provided. Incremental controls are provided for adaptive process optimization.
    Type: Grant
    Filed: January 21, 1986
    Date of Patent: February 16, 1988
    Assignee: Ortwin Hahn
    Inventors: Ortwin Hahn, Mohamed-Hussein Tiba
  • Patent number: 4721391
    Abstract: An impingement mixing device for preparation of plastic parts or objects including cellular foam from at least two reactive synthetic components and an auxiliary component such as liquid foaming agent and including at least two injection ports and a third port for input of the auxiliary component. Inert gas optionally and a foaming agent and further additives are mixed at a point in the cylindrical wall of the component mixing chamber located in or near the vicinity of the radial plane passing through the component openings. The introduction of the inert gas, foaming agent, coloring agent, or further additives is controlled by a cleaning piston which also simultaneously cleans the mixed plastic material penetrated therein from the opening area of the inert gas feeder line. The cleaning piston is part of a control piston, which with its rear segment is located in a metering chamber for the inert gas and optionally also for the foaming agent and the additives.
    Type: Grant
    Filed: April 1, 1986
    Date of Patent: January 26, 1988
    Assignee: Krauss-Maffei A.G.
    Inventor: Adolf Bauer
  • Patent number: 4714579
    Abstract: Plastics-forming materials are shaped in a mold tool sealed by an associated closing unit. Lifting elements the stroke of which can be limited and controlled are associated with the mold tool. Shaping is accomplished by filling the mold cavity with reaction mixture while the mold tool halves are not completely sealed, sealing the filled mold and keeping the mold sealed until the article is completely cured. This method and apparatus are particularly useful in the production of dimensionally accurate geometrically complicated shaped articles.
    Type: Grant
    Filed: June 4, 1986
    Date of Patent: December 22, 1987
    Assignee: Bayer Aktiengesellschaft
    Inventors: Heinrich Boden, Walter Schneider
  • Patent number: 4714575
    Abstract: A polyurethane RIM method has two mixheads. Reactants are brought to each mixhead and are supplied as separate streams to two spaced cavities in a mold having a pre-formed porous mat separating the two cavities. One stream contains an isocyanate, polyol, chain extender and crosslinker selected to have a very low viscosity and which reacts to produce a high modulus armature or load bearing member. The other stream contains a polyol and isocyanate with additives that have relatively high viscosity to produce a semi-rigid polyurethane foam. At each mixhead the proportions of ingredients are controlled to give a desired isocyanate index to control the flex modulus and other properties of the loading bearing member and foam molded components of the product. The low viscosity material penetrates the porous mat to reinforce it and the porosity of the mat prevents the high viscosity material from entering the armature cavity so as to reduce the load capacity of the finished product.
    Type: Grant
    Filed: May 27, 1986
    Date of Patent: December 22, 1987
    Assignee: Ex-Cell-O Corporation
    Inventor: Frank J. Preston
  • Patent number: 4708625
    Abstract: A mold closing assembly having two platen supporting bodies or turrets mounted on a base to pivot in a generally horizontal plane about two vertical pivot axes. At least one platen reciprocates linearly to clamp the mold sections together, and a tie bar extends above the two turrets between the pivot points. Preferably the mold closing assembly has a modular construction.
    Type: Grant
    Filed: April 11, 1986
    Date of Patent: November 24, 1987
    Assignee: C & F Stamping Co., Inc.
    Inventor: Donald P. Arend
  • Patent number: 4698371
    Abstract: The invention relates to a process for the preparation of cellular or non-cellular polyurethane-polyurea molded articles. The new process involves the use of urethane and isocyanurate group modified 2,4- and/or 2,6-toluene diisocyanate mixtures as the polyisocyanate component to improve the flowability of the reaction mixture without adversely affecting the mechanical properties of the resulting molded articles.
    Type: Grant
    Filed: September 26, 1985
    Date of Patent: October 6, 1987
    Assignee: BASF Aktiengesellschaft
    Inventors: Frank Werner, Matthias Marx, Hans U. Schmidt
  • Patent number: 4674170
    Abstract: A method for making a ball having a cover and a core, which core has a spherical center and a winding, is disclosed. The ball is made by foam injection molding a thermoplastic resin comprising a mixture of at least about 45% of a copolymer of at least one olefin with at least one unsaturated monocarboxylic acid to form a spherical partially blown center. The center is then wound to form a wound core which is immersed in an adhesive which impregnates the yarn. The wound core is then dried and ironed the melt the surface of the center so as to fuse the windings to the center. A cover is then applied to the core to form the completed ball.
    Type: Grant
    Filed: September 30, 1985
    Date of Patent: June 23, 1987
    Assignee: Athlone Industries, Inc.
    Inventors: David W. Hubbert, Bobby L. Robinson
  • Patent number: 4661391
    Abstract: The present invention relates to a method for the manufacture of moulded bodies such as cornices from foam plastics material, the visible side of these bodies being heavily textured or profiled, smooth, non-porous and free from separation elements, with a unit weight of less than 200 kg/m.sup.3. In the method, a thin, elastic, heat-deformable film (3) is inserted between two heated mould portions (1, 2) in such a way that the film edges are clamped between the superimposed mould edges of the two mould portions (1, 2), a reactive, heat emitting, foaming plastics mixture is introduced through the upper mould portion (1) in such a way that it may be distributed on the film, and the hollow chamber formed between the film and the lower mould portion is evacuated during foaming, such that the film intimately conforms to the shape of the lower mould portion.
    Type: Grant
    Filed: December 20, 1984
    Date of Patent: April 28, 1987
    Assignee: Noel, Marquet & Cie. S.A.
    Inventors: Ralph Schroder, Hans Despineux
  • Patent number: 4657716
    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.
    Type: Grant
    Filed: November 30, 1984
    Date of Patent: April 14, 1987
    Assignee: Lim Kunststoff Technologie Gesellschaft
    Inventor: Oskar J. Schmidt
  • Patent number: 4650620
    Abstract: In a filament winding technique, filaments are wound around a mandrel, and the mandrel remains in the structure and becomes part, normally a structural part, of the article. The mandrel may be any suitable rigid, light-weight material, but a foamed material such as a structural foam is thought to be most suitable. Metal inserts for attaching other components to the filament wound article can be moulded into the mandrel surface, and locked in place by the filament windings. According to a preferred aspect of the invention a motor vehicle suspension wishbone is made according to such filament winding method and the mandrel on which the filaments are wound remains in the structure.
    Type: Grant
    Filed: February 25, 1985
    Date of Patent: March 17, 1987
    Assignee: Ford Motor Company
    Inventors: Michael J. Owen, Victor Middleton, Kevin L. Edwards
  • Patent number: 4645630
    Abstract: The present invention relates to a process for the production of polyurethane-urea or polyurea-based microcellular of foam moldings by reacting a polyisocyanate component containing aromatically bound isocyanate groups with an isocyanate-reactive component containing at least one compound which has at least three aliphatic ether groups and aliphatically bound isocyanate-reactive groups and wherein a portion of the aliphatically bound-reactive groups are amino groups which have been converted to ammonium carbamate, carbonate or bicarbonate groups.The present invention also relates to the compounds containing aliphatic ether groups and ammonium carbamate, carbonate or bicarbonate groups, optionally in admixture with compounds containing unmodified amino groups or other known isocyanate-reactive compounds.
    Type: Grant
    Filed: August 30, 1984
    Date of Patent: February 24, 1987
    Assignee: Bayer Aktiengesellschaft
    Inventors: Werner Rasshofer, Hans-Joachim Meiners, Klaus Seel, Hans-Georg Wussow
  • Patent number: 4640808
    Abstract: Method for making magnetic rolls having a plurality of magnets integrally set fast with a retaining member at stated portions of the periphery of a roll shaft thereby forming a magnetic force generating part, in which the retaining member is made from a rigid synthetic resin or resin foam, and optionally having a strain absorbing groove at a portion outside of said magnetic force generating part are provided.
    Type: Grant
    Filed: January 18, 1985
    Date of Patent: February 3, 1987
    Assignee: Yamauchi Rubber Industry Co., Ltd.
    Inventors: Kunio Okumura, Yasuo Fukuyama, Atsuo Tanaka
  • Patent number: 4640150
    Abstract: A steering wheel having the hand wheel part thereof formed of an injection molded foam of thermoplastic synthetic resin, which injection molded foam has a substantially solid outer surface and is covered with a coating. This steering wheel is produced in attractive appearance without requiring use of any specially formulated resin material or exercise of rigid control of molding conditions.
    Type: Grant
    Filed: December 14, 1984
    Date of Patent: February 3, 1987
    Assignee: Toyoda Gosei Co., Ltd.
    Inventors: Teruo Kobayashi, Sadao Uchida
  • Patent number: 4636531
    Abstract: The invention relates to a process for the preparation of cellular, microcellular and noncellular polyurethane polyurea molded parts through the reaction of organic polyisocyanates, polyols having at least 2 reactive hydrogen atoms, and a chain extender containing at least 70 percent by weight of a mixture of aromatic diamines comprising from 80 to 50 weight percent of at least one primary aromatic diamine whose amino groups are sterically hindered relative to reaction with polyisocyanates, and 20 to 50 weight percent of at least one unsubstituted or substituted reactive primary aromatic diamine whose amino groups do not exhibit reduced reactivity to polyisocyanates.These reactive mixtures produce polyurethane polyurea polymers with excellent demoldability without the use of external mold release agents.
    Type: Grant
    Filed: February 13, 1985
    Date of Patent: January 13, 1987
    Assignee: BASF Aktiengesellschaft
    Inventors: Hans U. Schmidt, Frank Werner
  • Patent number: 4634563
    Abstract: A pre-shaped aluminum plate is held against the flat end wall of an inverted mold cavity by vacuum pressure communicated through bore holes in the wall leading to a vacuum chamber in the mold body. A high temperature PTFE gasket shaped to match the plate fits in an annular recess in the wall to provide a seal between the wall and plate. Polyurethane foam expands and hardens in the mold cavity to further press the plate against the wall and to form a foamed plastic water ski having a flush aluminum deck. The mold cavity has a curved side wall to produce a ski having a radiused edge about the deck.
    Type: Grant
    Filed: December 10, 1984
    Date of Patent: January 6, 1987
    Assignee: Texas Recreation Corporation
    Inventor: Kendal Hancock
  • Patent number: 4608214
    Abstract: The present invention is directed to a process for the production of optionally cellular, polyurethane and/or polyurethane-urea moldings having an impervious skin by reacting in a closed mold a reaction mixture containing(a) at least one organic polyisocyanate,(b) at least one compound which has a molecular weight of about 400 to 12,000 and at least two isocyanate-reactive groups, and(c) optionally at least one compound which has a molecular weight of from 32 to 399 and at least two isocyanate-reactive groups,wherein before the reaction takes place a surface-improving additive (e) is added containing(e1) a liquid and sedimentation-stable polymer dispersion which is produced by the free radical addition polymerization or copolymerization of one or more olefinically unsaturated monomers in a high molecular weight compound having isocyanate-reactive groups of the type mentioned in (b),and optionally(e2) a metal salt of a monocarboxylic acid having at least 8 carbon atoms in the moleculewherein additive (e) is us
    Type: Grant
    Filed: December 21, 1984
    Date of Patent: August 26, 1986
    Assignee: Bayer Aktiengesellschaft
    Inventors: Gerhard Balle, Reiner Paul, Werner Rasshofer
  • Patent number: 4607090
    Abstract: This invention relates to reaction injection molded elastomers derived from high molecular weight amine terminated polyethers and/or high molecular weight polyols, a chain extender, a polyisocyanate, an epoxy silane coupling agent, and untreated filler material. The reaction injection molded (RIM) elastomers of this invention are useful, for example, as automobile body parts.
    Type: Grant
    Filed: August 8, 1985
    Date of Patent: August 19, 1986
    Assignee: Texaco Inc.
    Inventor: Richard J. G. Dominguez
  • Patent number: 4590219
    Abstract: The invention relates to a process for the preparation of elastomeric molded parts having urethane or urethane and urea linkages which comprises reacting(a) an organic polyisocyanate,(b) a polyhydroxyl compound selected from the group consisting of(i) polyester polyols with molecular weights of 1000 to 3000 and hydroxyl numbers of 170 to 35 produced by polycondensation of organic dicarboxylic acids and a polyol mixture of at least 3 polyols;(ii) polyether polyols having terminal ester groups, molecular weights of 1000 to 8000 and hydroxyl numbers of 170 to 15; and(iii) mixtures thereof;(c) a chain extenderwherein components (a) through (c) are processed according to reaction injection molding techniques in open or closed molds.The reaction is preferably carried out as a one-shot process and may also be carried out in the presence of blowing agents (d), auxiliaries (e), and additives (e).
    Type: Grant
    Filed: April 22, 1983
    Date of Patent: May 20, 1986
    Assignee: BASF Aktiengesellschaft
    Inventors: Dietmar Nissen, Matthias Marx, Hans U. Schmidt
  • Patent number: 4590023
    Abstract: Method of manufacturing an injection-molded ski plate comprising steps of disposing a lower side member in a lower mold, disposing an upper side member in the lower mold, disposing an upper mold formed with a concaved portion corresponding to a roof-like shape with the widthwise central part of the ski plate and injecting a foaming synthetic resin into a hollow space between the lower and upper members and harding after foaming, whereby the upper member is molded following the roof-like concaved portion so that a convexed roof-like portion is formed on the upper member.
    Type: Grant
    Filed: May 14, 1984
    Date of Patent: May 20, 1986
    Assignee: Mizuno Corporation
    Inventors: Keijiro Hayashi, Toshimi Awano, Shigeru Asai
  • Patent number: 4588542
    Abstract: A bicycle wheel assembly prepared by a process comprising the steps of:(a) Inserting a bicycle rim assembly comprising a central hub, a plurality of radially extending spokes joined to said hub at one end and a rim having a channular cross section joined to the opposed ends of the spokes into a mold cavity configured to form a bicycle tire around the rim;(b) Injecting a foamable polyurethane composition into said mold cavity;(c) Foaming and curing the polyurethane composition in the mold cavity; and(d) Cooling the so-foamed polyurethane composition to cause it to shrink fit around the rim.
    Type: Grant
    Filed: May 4, 1981
    Date of Patent: May 13, 1986
    Assignee: G. P. Plastics, Inc.
    Inventor: Owen A. Pierce
  • Patent number: 4585850
    Abstract: This invention relates to reaction injection molded elastomers derived from high molecular weight amine terminated polyethers and/or high molecular weight polyols, a chain extender, a polyisocyanate, and flaked glass treated with an amino, chloro, and/or isocyanate silane coupling agent. The reaction injection molded (RIM) elastomers of this invention are useful, for example, as automobile body parts.
    Type: Grant
    Filed: August 30, 1984
    Date of Patent: April 29, 1986
    Assignee: Texaco Inc.
    Inventor: Richard J. G. Dominguez