Abstract: A mold assembly for making a multilayer molded article comprising: a first mold; a second mold; a shut-off pin slidably received in a resin-supplying gate opened to a cavity face of the first mold; a pin-driving unit for moving the shut-off pin among an opening position, a closing position and a projecting position; a resin-supplying unit for supplying a molten thermoplastic resin from said resin-supplying gate; and a press unit for moving the molds between an open position and a closed position.

Abstract: A method and an apparatus are disclosed for producing plastic objects with solid regions and hollow regions. The method has the following steps: a) blocking off a part of the cavity (2) of a molding tool (1), so that little or no plastic melt can reach the blocked-off region (8); b) injecting plastic melt into the unblocked region (9) of the cavity (2) of the molding tool (1); c) releasing the blockage, so that plastic melt can reach the previously blocked-off region (8) of the cavity (2); d) injecting a pressurized gas into the melt by means of at least one fluid injection nozzle (7), so that the melt injected into the molding tool is distributed into the desired regions of the cavity (2) while forming a hollow space and is pressed against the cavity walls of the molding tool (1); e) allowing the molded part (6) to cool; f) relieving the cavity (2) of the pressure of the pressurized fluid; and g) demolding the molded part.

Abstract: A method and apparatus for making a multi-colored, injection molded product. A nozzle which has at least two separate feed passageways receives the primary resin stream from the primary feed tube. Two separate fluid-operated cylinders add different colorant masses to the separate portions of the feed stream through lateral openings into the two passageways. Blending of the two different masses is prevented in the nozzle and blending with the primary resin stream is minimized during feed to the mold to optimize the brightness of the colors in the end product.

Abstract: A coinjection molding system for injecting skin and core material into a mold cavity. The system includes a three position actuator for moving a valve pin into a closed position in which neither skin nor core flow is permitted, a middle position in which only skin flow is permitted, and an open position in which skin and core flow is permitted. The actuator includes a first piston slidably mounted in an actuator housing, and a second piston, attached to the valve pin, slidably mounted within the first piston. A shut-off is provided in the manifold for preventing skin flow to a particular nozzle during sequential gating.

Abstract: A color slide fastener and a method and apparatus for fabricating the same are disclosed.

Abstract: Mold bushings or nozzles for gas-assisted injection molding processes are disclosed. The devices include movable shut-off mechanisms which selectively facilitate or prevent the passage of molten plastic material into mold cavities. One or more apertures, such as holes, openings, channels, slits, slots, and the like, are provided at or adjacent the end of the pin members or at the end of the devices. The apertures are thin or small and have dimensions which will allow the passage of gas and at the same time prevent the plastic material from plugging or clogging them.

Abstract: A method for fabricating a casing having tubular screw posts includes injection molding a resin composition in a mold to form the casing by introducing a pressurized gas into the resin composition through gas supplying pins to form hollow parts in the resin composition, providing the gas supplying pins with an outer diameter conforming to an inner diameter of the tubular screw posts, positioning the gas supplying pins in a mold at preset locations where the tubular posts must be formed, forming bores in the preset locations by removing the gas supplying pins from the preset locations before the resin composition is hardened, and providing internal screw members in the bores.

Abstract: There is provided a process for producing a multi-layer molded product having a plurality of thermoplastic resin layers. This process provides for (i) a step of supplying first and second molten thermoplastic resins each through first and second resin supplying gates which are temperature-controllable independently of each other, to between female and male molds kept in an open state with a time difference being provided between supply starts of the first and second resins, and (ii) a step of closing the female and male molds after completion of supply of the first and second resins. The process enables production of high-quality multi-layer molded products having a plurality of resin layers with good repeatability under relatively low resin supply pressure and by single mold closing. Further, high-quality multi-layer molded products can readily be produced without restrictions on materials used.

Abstract: An injection molded product, having an array of fastener elements integrally molded with and extending from a surface of the product, is molded in a closed cavity die. One half of the die has a mold surface with a region having an array of fastener element cavities extending therefrom for molding the fastener elements. The other half of the die has a mold surface aligned with the mold surface of the first mold part to define therebetween, in a closed condition, a mold cavity constructed to receive molten plastic for molding the product. The mold cavity includes a first portion comprising a majority of the volume of the mold cavity, and a second portion contiguous with the first portion and defined in part by the region of the first mold part surface having the array of fastener element cavities.

Abstract: A readily replaceable pin-in-sleeve device (A, B) for gas-assisted injection molding is used with a two-part mold to form an injection molded product from a plastic material. A sleeve (10) has a threaded exterior surface that is shaped to be received in a socket (130) of a mold member (210) opening into a mold cavity. A longitudinally extending bore (20) extends through the sleeve. The bore has a first portion (22) adjacent the cavity, and a second, larger diameter portion (24), spaced from the cavity. A pin (40) extends through the sleeve and has a forward section and an enlarged base, which are received in the bore first and second portions, respectively. A tortuous path for an injection fluid is defined between the pin and the bore to inhibit transport of plastic material into the device when the injection fluid is vented from the mold cavity. A filter 60 positioned in the bore, behind the pin, filters traces of plastic material from the vented injection fluid.

Abstract: A partition member having partition walls arranged in a lattice is disposed in the vicinity of an upper surface of a molten metal mass. The upper surface is divided by the partition walls into a multiplicity of segmental surfaces. A forming starter member is brought into contact with the partition member so that the molten material adheres to a starter surface of the forming starter member, and is then separated from the partition member. The molten metal is drawn from each of the segmental surfaces, and the drawn metal is solidified to form a piece which has a cross sectional shape corresponding to the shape of the starter surface. With the use of forming starter members having respective starter surfaces which are different in shape from each other, it is possible to form pieces having various cross sectional shapes which correspond to the shapes of the starter surfaces.

Abstract: The hot-runner coinjection distributor block arrangement comprises several block parts (6, 7) which with the help of heating elements (8) may be brought to differing temperatures. These block parts (6, 7) are spaced from one another with an intermediate piece (9) and are supported via a support element (10) on the head plate (2). In this support element (10) spring elements, preferably a disc spring (11) is incorporated, which spaces the support element (10) from the head plate (2) and press the two block parts (6, 7) onto one another also in the cold mode. In the hot mode these disc springs (11) permit an axial expansion of the block parts (6, 7) and reduce the tension force exerted onto the support element (10). Peg-like formations of the intermediate piece (9) and of the support element (10) ensure that the bores for the guiding of the closure needle or of the feed channel (13) by the thermal expansion of the block parts (6, 7) are retained, i.e. are not laterally displaced.

Abstract: A decorative food formed of a plurality of kinds of fluid food materials and manufactured by using a mold is provided. The decorative food has an outside shape thereof conforming to an interior surface of the mold inclusive of an opening of said mold. The decorative food has a colored pattern divided into multiple divisions extending up to a central portion of the decorative food, in a direction to extrude the food materials into the mold, the colored pattern being formed such that the multiple divisions are arranged with substantially the same ratio at any of a cross sectional area intersecting the direction to extrude the food materials, and wherein the decorative food contains therein a foodstuff. Also disclosed are an apparatus and method for manufacturing the decorative food.

Abstract: A manifold for a multiple injection unit injection molding machine that allows the machine to be used when a standard conventional mold is attached to a platen. The manifold includes a first inlet port that is in communication with one nozzle of the machine and a second inlet port that is in communication with another nozzle of the machine. Each inlet port communicates with an inlet passage and the two inlet passages join an exit passageway at a junction. The exit passageway is in communication with an exit port to transfer fluid to a mold cavity. The manifold has a valve located at the junction to control the flow of material through the exit passageway.

Abstract: An apparatus for forming magnetized rotating elements for a rotating element display where all the elements are magnetized in the same orientation is disclosed. The apparatus comprises at least one separator member. Each separator member has a diameter, two opposed surfaces and an edge region in contact with both of the surfaces. Further included is an apparatus for providing at least two liquid flows wherein each one of the liquid flows has an associated separator member and an associated surface on the associated separator member, and each one of the liquid flows is provided across the associated surface of the associated separator members. The liquid flow flows toward the edge region of the associated separator member. The liquid flows are each a flow of hardenable liquid material associated with an optical modulation characteristic, and at least one of the liquid flows containing a magnetic pigment.

Abstract: A method and an apparatus for forming a panel of packaged integrated circuits is disclosed. A substrate panel having an array of integrated circuits mounted thereon is placed in a mold having a molding chamber. The molding chamber has a multiplicity of adjacent package recesses flowably interconnected by way of a plurality of molding compound flowgates. Each package recess is suitable for receiving at least one associated integrated circuits. A molding compound is passed into the molding chamber by way of a mold gate such that at least some of the molding compound passes through a plurality of different package recesses by way of their associated flowgates. In one embodiment, the mold includes a mold body having a molding chamber with a plurality of ridges that define the multiplicity of package recesses within the molding chamber. The multiplicity of package recesses are flowably interconnected through flowgates formed by the ridges.

Abstract: A multi-cavity coinjection mold and method for simultaneously producing a plurality of multi-layered articles comprising: a mold structure defining a plurality of mold cavities; a first supply source for supplying metered amounts of a first molding material; a second supply source for supplying metered amounts of a second molding material; a hot runner system in communication with the first and second supply sources for conveying the metered amounts of the first and the second materials separately to a region proximate each of the cavities; a valve mechanism per cavity for receiving the metered amounts of the first and second materials from the hot runner system and for sequentially supplying desired quantity of the first and second materials contiguously to each cavity.

Abstract: At least one mold is provided having a mold cavity and a mold gate communicating with the mold cavity, an injection nozzle for feeding molten plastic material to the injection mold having a nozzle outlet in line with the mold gate, and a thin movable valve gating arrangement positioned between the mold gate and nozzle outlet having an orifice therein permitting and shutting off flow of molten plastic from the nozzle to the mold.

Abstract: At least one mold is provided having a mold cavity and a mold gate communicating with the mold cavity, an injection nozzle for feeding molten plastic material to the injection mold having a nozzle outlet in line with the mold gate, and a thin movable valve gating arrangement positioned between the mold gate and nozzle outlet having an orifice therein permitting and shutting off flow of molten plastic from the nozzle to the mold.

Abstract: The present invention is an injection compression molding method and apparatus therefor which are capable of using a simple structure for rapidly molding a multilayer molded product with high strength and high accuracy. A molding method for attaining such characteristics includes the steps of extending an injected molten resin (51) by compressing the same in metal molds (31, 32), opening the metal molds during or after the extending operation, injecting a surface layer material (60) into a cap (.delta.) occurring between the metal molds (31, 32) and the molded resin (51) when the molds are opened, closing the molds during or after the injecting of the surface layer material (60), and cooling the resin (51) and the surface layer material (60) in the closed metal molds (31, 32).

Abstract: A method and an apparatus are disclosed for producing plastic objects with solid regions and hollow regions. The method has the following steps: a) blocking off a part of the cavity (2) of a molding tool (1), so that little or no plastic melt can reach the blocked-off region (8); b) injecting plastic melt into the unblocked region (9) of the cavity (2) of the molding tool (1); c) releasing the blockage, so that plastic melt can reach the previously blocked-off region (8) of the cavity (2); d) injecting a pressurized gas into the melt by means of at least one fluid injection nozzle (7), so that the melt injected into the molding tool is distributed into the desired regions of the cavity (2) while forming a hollow space and is pressed against the cavity walls of the molding tool (1); e) allowing the molded part (6) to cool; f) relieving the cavity (2) of the pressure of the pressurized fluid; and g) demolding the molded part.

Abstract: An injection molding apparatus capable of producing injection molded articles from at least two plastic melts, includes an additional mold mounting device between a fixed mold mounting plate and a movable mold mounting plate that is traversed along four essentially horizontal tie rods. The additional mold mounting device is also pivotable around a rotational axis aligned perpendicular to the longitudinal axis of the tie rods, and carries additional mold halves that cooperate with the mold halves mounted on the mold mounting plates on at least two side surfaces that are aligned with a spacing parallel to each other and relative to the rotational axis. The additional mold mounting device comprises upper and lower support blocks that are arranged at a spacing relative to each other in an essentially vertically aligned plane, with each support block being guided on at least of the two tie rods. A friction or pivot bearing is provided for vertically aligned pivots of a prismatic mold core support.

Abstract: Multi-layer injection molding apparatus having integral multi-layer melt dividing bushings seated in the melt distribution manifold for dividing a first melt passage extending to annular melt channels in heated nozzles. Matching melt channels machined in the front face of the first layer and the rear face of the second layer of each melt dividing bushing form a melt conduit which branches from an inlet to two spaced holes extending through the second layer. A pair of matching melt channels machined in the front face of the second layer and the rear face of the third layer of each melt dividing bushing form two melt conduits, each of which branch from one of the holes through the second layer to two of four spaced holes through the third layer. The four holes through the third layer align with four melt bores leading to the annular melt channel in one of the heated nozzles. A second melt passage may extend through a central bore in each melt dividing bushing to a central melt channel in the heated nozzle.

Abstract: A multi-cavity coinjection mold having a relatively large plurality of cavities for simultaneously molding a relatively large plurality of multi-layered articles including a) a plurality of cavity groups each defining a relatively small plurality of said cavities, a single balanced hot runner for supplying said relatively small plurality of cavities with contiguous different plastics materials, and a valve for sequentially supplying desired contiguous quantities of the plastics materials from plastics material sources, common to all of said groups, to the balanced hot runner; and b) a hot runner manifold system connected to the plastic material sources to supply the plastic materials to all of the valves; and related methods.

Abstract: A process for forming a product having multiple and well defined color patterns. In a first embodiment, the rotomolding process comprises a first step of using a first powder having a first color and a second powder having a second color which is different than the color of the first powder. The rotomolding process comprises a second step of placing the first and second color powders into a pre-determined pattern within a hollow cavity mold. The rotomolding process comprises a third step of placing the closed hollow cavity mold into the oven. The rotomolding process comprises a fourth step of heating the hollow cavity mold with no rotation for a first period defined by the heating time necessary for a layer of individual colors to melt in the desired pattern upon the inside surface of the hollow cavity mold.

Abstract: There is provided a multi-layer molding method by which a molding product of multi-layers, in which a second layer is locally formed on a base layer, is produced, and the multi-layer molding method comprises the steps of: forming locally a cavity for forming the second layer between the first mold and the second mold; injecting a second resin into the cavity for forming the second layer so as to mold the second layer; separating relatively the first mold and the second mold from each other so as to form a cavity for molding a base layer continuously between the first and the second molds and also between the second layer and a mold surface opposing to the second layer; and injecting resin for the base layer into the cavity for molding the base layer.

Abstract: A process for forming a molded article having a multilayer structure which comprises successively injecting melts of at least two materials into the cavity portion of a mold, solidifying a part thereof in the cavity portion to form the multilayer structure, characterized in that as a first step, one of the molten materials is injected into the cavity portion and the portion of the injected molten material contacting with the mold surface is solidified to a predetermined thickness to form a skin layer; as the second step, the next molten materials is fed into the cavity, the unsolidified portion of the molten material previously fed is pushed out of the cavity and a part of the thus fed molten material is cooled and solidified from the surface of the mold to form the next layer; and the procedure of the second step is successively repeated using the remainder of the molten materials alternately, and the molded article produced by the above molding process.

Abstract: A mold for use in a gas-assisted injection molding system includes a gas pin assembly which can be readily removed from one mold half in an open position of a mold wherein a porous insert of the assembly can also be readily removed from the housing of the assembly for easy servicing. The housing of the assembly has an elongated aperture formed therethrough in communication with a gas passageway in the mold to permit the flow of gas therethrough. The porous insert is positioned in the aperture. The insert permits the flow of gas therethrough but prevents the passage of molten plastic therethrough. The assembly also includes a holding device preferably in the form of a set screw which has a gas hole formed completely therethrough to permit the flow of gas therethrough. The set screw is threadedly secured within the housing to hold the insert stationary within the aperture and to permit ready removal of the insert from the housing after the set screw has been removed from the housing.

Abstract: Molds useful in the production of polythermal plastic resin articles are disclosed. One of the molds disclosed contains a set of a female mold member and a male mold member having opposing mold surfaces respectively, wherein at least one of the mold members has a gas passage therein; and a gas introducing member having a tip and a gas path extending therethrough, the gas introducing member being disposed in at least one of the mold members such that the tip does not protrude from its respective mold surface, the gas path being in communication with the gas passage, wherein the gas introducing member is a molded piece having at least one of grooves in a peripheral part or penetrating holes through an interior thereof, with the grooves and holes communicating with the gas passage.

Abstract: A method and apparatus for molding a one-piece article in a single molding operation using two different plastic materials so a first portion of the article is made of one plastic material and a second portion of the article is made of a different plastic material, and the two portions are fused together while hot to create a one-piece article.

Abstract: A pressure-activated valve for conducting pressurized gas into a mold cavity of an injection molding apparatus is preferably constructed as an easily replaceable unit. The preferred valve includes a pin having a flared head section. The head section has a planar face transverse to an axis of the pin so as to approximately conform to a neighboring contour of the mold cavity. The valve also includes a body in which a passageway intersects a second end of the body to define a port and a flaring seat communicates through a first end of the body between the passageway and the mold cavity. A restrainer which abuts against the second end of the body includes a guideway aligned with the passageway through the body as well as at least one cross-channel which admits pressurized gas to that passageway through the port. The pin extends through both the passageway and the guideway so that its head portion is positioned near the seat.

Abstract: An injection molding machine for simultaneously injection molding a plurality of articles each made of plural polymeric materials. The injection molding machine includes a source of a first polymeric material and a source of a second polymeric material. The injection molding machine also includes a plurality of co-injection nozzles, each of the nozzles has an associated injection cavity mold. Each of the nozzles also has a first flow channel for providing a stream of said first polymeric material to said mold and a second flow channel for providing a stream of said second polymeric material to said mold. The machine further includes a manifold for feeding the polymeric materials from their sources to each of the nozzles and each of the associated molds, such that each of the streams of the first polymeric materials flows from each nozzles into each associated mold simultaneously and each of the streams of the second polymeric materials flows from each nozzle into each associated mold simultaneously.

Abstract: Valve gated multi-cavity injection molding apparatus for five layer molding having actuating mechanisms for reciprocating elongated valve members between four different positions. Each actuating mechanism has a front and a rear aligned cylinders, a first piston connected to the head of one of the valve members in the front cylinder and second and third pistons in the rear cylinder. The third piston has a stem portion which extends forwardly through the second piston into the front cylinder. Hydraulic pressure from four hydraulic lines connected to each actuating mechanism reciprocates each elongated valve member between the different positions. In the first closed position, the front end of the valve member is seated in the gate. In the second position, the front end of the valve member is retracted sufficiently to allow an initial amount of PET to flow from an outer annular melt channel through the gate.

Abstract: A multilayer injection molding machine manufactures a molded product formed of a plurality of layers of resins or colors by press fitting resins from a core layer injection unit and a skin layer injection unit to a cavity part formed by pressing and clamping a moving metal mold to a fixed metal mold fixed to a support member. The multilayer injection molding machine is formed by integrating a connecting device body interposed between the fixed metal mold and the support member so as to support the fixed metal mold to the support member and an injection unit connecting device provided on the connecting device body and having a plurality of resin passages allowing the cavity part to communicate with each injection unit.

Abstract: A system for the spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as powders, whiskers or fibers.

Abstract: The invention comprises a plasticating machine for the working and forcing of plastic material into a mold, the machine including an elongated barrel housing having a first or proximal end and a second or distal end, and an elongated screw shaft with a screw flight therearound, the screw shaft being rotatably supported in the elongated barrel housing, for the working of plastic between the screw shaft and the elongated housing. At least one delivery conduit is generally longitudinally arranged within the wall of the housing. The delivery conduit with the housing wall may be arranged to heat or cool the screw and any plastic being worked therethrough. In a further embodiment, it may permit delivery of a medium within the wall, from an upstream location of the housing, into the primary flow path of any plastic being driven from the machine and into a mold.

Abstract: In the method according to the invention, as shown in the drawings, the elastomeric skin is manufactured in a mold assembly having a mold surface (2), a portion (3) of which is shielded off by means of a mask (4), a first elastomeric material (7) is sprayed on this mold surface (2), the mask (4) is removed, and a second elastomeric material (9) is sprayed on said portion (3) of the mold surface (2). The edges (11) of the mask (4) are placed on top of upstanding edges (13) of the mold surface (2) so that the transition between both elastomeric materials (7, 9) is achieved on these upstanding edges (13), i.e. in an outer recess of the elastomeric skin resulting in an aesthetic visual parting line. According to a further important aspect, the edges (11) of the mask (4) are maintained at a distance from the mold surface (2) such as to avoid contact between the layer of first elastomeric material (7) sprayed onto the mold surface (2) and the mask (4).

Abstract: A process for producing a bumper for a vehicle uses a first step of injecting an outer layer forming material into a bumper forming cavity through a gate in a mold, and a second step of injecting a core forming material, thereby allowing the core forming material to flow into the outer layer forming material existing in said gate and said cavity, while allowing the outer layer and core forming materials to flow within the cavity. In the mold, the volume of a mounting portion forming area of the bumper forming cavity is set so that the thickness t.sub.1 of at least a mounting portion of the bumper for mounting to a vehicle body to extend laterally from a central portion of the vehicle body can be larger than the thickness t.sub.2 of a bumper main portion excluding the mounting portion, and the gate opens into the mounting portion forming area.

Abstract: A method of reducing uncontrolled flow of a molten polymer during the packing and cooling stage of an injection molding cycle. A plurality of polymers are injected between a mold cavity and core for making a multilayer plastic article such as a preform, having an exterior layer of a first polymer and an interior layer of a second polymer. In a tapered region of the mold, a minimum width of the tapered region is selected to prevent the second polymer from developing an enhanced leading/trailing edge effect which causes the second polymer to reverse flow during the packing and cooling stage. The method is particularly useful for making preforms for blow molded containers, such as a ketchup container, having a relatively long and thin neck profile. In addition, the method maintains the interior (barrier) layer a minimum distance from the top sealing surface of the preform, in order to prevent defective heat-bonded seals.

Abstract: A mold for use in a gas-assisted injection molding system having a nozzle includes a runner shut-off subsystem which prevents pressurized gas from flowing through the runner and into the nozzle. A pair of pins are preferably mounted on a plate to move therewith between extended and retracted positions of the plate. The pins are slidably fit within one mold half of the mold to move within the runner between extended gas-blocking positions to block the flow of pressurized gas through the runner and into the nozzle and retracted positions to allow the flow of molten plastic from the nozzle, through the runner, through a gate, and into an article-defining cavity in a closed position of the mold. The runner shut-off subsystem includes a hydraulic cylinder for moving the plate and the pins relative to the mold half. Each of the pins has a free end portion which extends into another mold half of the mold where it is received and retained in its extended gas-blocking position.

Abstract: A coinjection molding system for injecting skin and core material into a mold cavity. The system includes a three position actuator for moving a valve pin into a closed position in which neither skin nor core flow is permitted, a middle position in which only skin flow is permitted, and an open position in which skin and core flow is permitted. The actuator includes a first piston slidably mounted in an actuator housing, and a second piston, attached to the valve pin, slidably mounted within the first piston. A shut-off is provided in the manifold for preventing skin flow to a particular nozzle during sequential gating.

Abstract: Sprue gated injection molding apparatus for molding preforms or other products having two layers of a barrier material such as EVOH or nylon alternating between three layers of another thermal plastic material such as PET. The PET is injected by one injection cylinder into first and third melt passages which branch in a front melt distribution manifold to extend to a number of heated nozzles. The first melt passage extends through a central melt channel in each heated nozzle and the third melt passage extends through an outer annular melt channel surrounding the central melt passage to an aligned gate leading to a cavity. The barrier material is injected by another injection cylinder into a second melt passage which branches in a rear melt distribution manifold to extend to an inner annular melt channel extending between the central melt passage and the outer annular melt channel in each heated nozzle.

Abstract: An outer layer forming material is injected into a cavity in a mold and then, a core forming material is injected, whereby the core forming material is allowed to flow into the outer layer forming material existing in the cavity, and both the materials are allowed to flow within the cavity. The cavity has a main area for forming a bumper main portion, and side areas for forming bumper sides. A relation, d.sub.1 >d.sub.2 is established between a distance d.sub.1 determining a bumper thickness of a first section for forming an upper portion of the bumper main portion and a distance d.sub.2 determining a bumper thickness of a second section for forming a lower portion of the bumper main portion. A relation, d.sub.3 >d.sub.1 is established between a distance d.sub.3 determining a bumper thickness of the side areas and the distance d.sub.1. A film gate opens into the first section.

Abstract: A mold for use in a gas-assisted injection molding system includes a gas pin assembly which can be readily removed from one mold half in an open position of a mold wherein a porous insert of the assembly can also be readily removed from the housing of the assembly for easy servicing. The housing of the assembly has an elongated aperture formed therethrough in communication with a gas passageway in the mold to permit the flow of gas therethrough. The porous insert is positioned in the aperture. The insert permits the flow of gas therethrough but prevents the passage of molten plastic therethrough. The assembly also includes a holding device preferably in the form of a set screw which has a gas hole formed completely therethrough to permit the flow of gas therethrough. The set screw is threadedly secured within the housing to hold the insert stationary within the aperture and to permit ready removal of the insert from the housing after the set screw has been removed from the housing.

Abstract: A mold for use in a plastic injection molding system includes a venting pin assembly which can not only vent an article-defining cavity in the mold but can also eject a formed plastic article in an open position of the mold. A porous insert of the assembly permits air from the article-defining cavity to flow there-through while preventing the passage of molten plastic from the article-defining cavity in a closed position of the mold. A venting pin of the assembly in the form of a hollow ejector pin has an elongated aperture formed therethrough to permit the flow of air therethrough. The porous insert is positioned in the aperture at a gas hole formed through an end surface of the ejector pin. The insert and the gas hole are sized so that the insert and the end surface help to form a "Class A" surface on the article formed in the article-defining cavity.

Abstract: A mold for use in a gas-assisted injection molding system includes an ejector pin subsystem including a blocking pin assembly which not only blocks the flow of molten plastic through a secondary runner but also helps to eject solid plastic from the mold. The mold also includes an adjustable overflow pin assembly and a conically-shaped spill cavity flow-coupled by the secondary runner to an article-defining cavity of the mold. The blocking pin assembly together with the adjustable overflow pin assembly are mounted on an ejector plate to move therewith between extended and retracted positions of the ejector plate. The blocking pin assembly includes a blocking pin which is slidably fit within a mold half to move between an extended blocking position to block the flow of molten plastic through the secondary runner and a retracted position to allow the flow of molten plastic through the secondary runner and into the spill cavity.

Abstract: A gas injection apparatus for use with a gas assisted injection molding system. The gas injection apparatus includes a mold part defining an elongated bore communicating upstream with a source of gas and downstream with a mold cavity, and an elongated pin positioned in the bore and coacting with the bore to define a gas flow passage therebetween for movement of gas from the gas source to the mold cavity. The bore and pin include first, second and third corresponding portions. The pin and bore define an annular axial clearance in the first portion, a close fit with an axial linear passage in the second portion and an annular axial passage in the third portion. This arrangement ensures that the pin will remain concentric with respect to the bore so as to discourage entry of resin into the annular axial passage.

Abstract: A mold for use in a gas-assisted injection molding system includes an ejector pin subsystem including a split pin which partially blocks the flow of molten plastic through a secondary runner, helps to eject solid plastic from the mold, and helps to define an article-defining cavity and the secondary runner in the mold. A first spill cavity is flow coupled by the secondary runner to the article-defining cavity. The split pin together with other ejector pins are mounted on an ejector plate to move therewith between extended and retracted positions. A second spill cavity is flow coupled by a tertiary runner to the first spill cavity if needed. The split pin, as well as the other ejector pins mounted on the ejector plate, eject plastic from the article-defining cavity, the spill cavities, and the secondary and tertiary runners in the extended position of the ejector plate.

Abstract: A molding system for use in producing a solidified article having a predetermined composite pattern formed of at least two kinds of viscous fluids distinct from each other in color, the system including: at least one discrete passage per each of the viscous fluids, and at least one discrete passage outlet per each of the viscous fluids separately guided through the at least one discrete passage, a method for producing the solidified article, an apparatus for producing the solidified article, and a method for producing the solidified articles.

Abstract: A process for the manufacture of polyurethane foam comprising the steps of (i) mixing at a reaction index of 40 to 400: (a) a polyisocyanate blend comprising at least one polyisocyanate and optionally, additives and fillers; (b) a polyol blend comprising isocyanate reactive components and optionally, water, additional blowing agents, catalysts, surfactants, fillers and other additives; wherein either or both said polyisocyanate blend or said polyol blend contain between 0.3 to about 20 wt. % CO.sub.2 based on the total weight of said polyisocyanate blend and said polyol blend; (ii) introducing and uniformly mixing in liquid form of CO.sub.2 as a blowing agent into either or both said polyisocyanate blend or said polyol blend and maintaining said CO.sub.2 in said liquid form. The present invention also relates to an apparatus, which performs the above-mentioned process.