5111 results about "Shell molding" patented technology

A golf club having a hollow golf club head which is filled with a gas under pressure. The interior surface of the golf club head is coated with a solidified layer of plastic material. The pressurized gas permits the use of thinner face plates by compensating for forces generated when the face plate strikes a golf ball. The plastic layer is preferably applied through the process of rotational molding using a thermoplastic material.

An imprint process comprises the step of aligning a substrate, supported on a first support member, with a template, supported on a second support member. The substrate has at least one essentially plane surface provided with a moldable film. The template has at least one essentially plane surface provided with a relief pattern. The relief pattern is adapted to interact with the moldable film. The process further comprises the step of arranging a sealing gasket between the template and the second support member, such that a pressure cavity is defined by the second support member, the template and the sealing gasket. The process also comprises the step of applying a static gas pressure to the pressure cavity, in order to provide a pressure between the template and the substrate. The pressure is sufficient to form a pattern in the moldable film. An imprint device is also disclosed.

A blend of a macrocyclic polyester oligomer and a polymerization catalyst as a one component ready-to-use material with a long shelf life enables production of parts from macrocyclic polyester oligomers without the modification of existing equipment, thereby reducing time and cost of manufacture while expanding the application of macrocyclic polyester oligomers. In this blend material, the macrocyclic polyester oligomer remains intact in solid state at ambient conditions. Upon melting, the blend material initially forms low viscosity fluid, and then rapidly polymerizes to form high molecular weight polyesters which subsequently solidify to form crystalline polymers. In the case of certain macrocyclic polyester oligomers, for example, poly(1,4-butylene terephthalate), demolding can take place at the polymerization temperature, e.g., at about 180° C. to 200° C., because the resulting polyester polymer solidifies fairly rapidly at that temperature without cooling. In one aspect, the invention generally features a blend material that includes a macrocyclic polyester oligomer, a polymerization catalyst, and optionally, a filler. In another aspect, the invention generally features a process for preparing a blend material. In yet another aspect, the invention features processes such as rotational molding, resin film infusion, pultrusion, resin transfer molding, filament winding, making and using powder-coated or hot melt prepreg, compression molding, and roll wrapping, which use the blend material.

Methods and apparatus for applying internal features or complex mechanical structures to a surface of a metal part are disclosed. According to one aspect of the present invention, a method for creating an assembly that includes a substrate and a molded piece involves obtaining the substrate, and forming at least one binding feature on a surface of the substrate. The method also includes molding on a surface of the binding feature and the surface of the substrate. Molding on the surface of the binding feature and the surface of the substrate mechanically binds the molded piece to the substrate.

The present invention relates to making optical articles such as opthalmic lenses by molding and, in particular, to using a continuous extrusion-compression molding method to make plastic lenses whereby a polymer melt is fed from an extruder or melting apparatus to a first die of a plurality of rotating or conveyed sequentially processed compression die sets comprising a first die and a second die. The die sets are positioned on die supports on a rotating turntable or conveying system, the lenses formed by compressing the die sets with pressing means associated with each die support, the lenses separated from the dies and the dies recycled to die loading and the melt feed step of the process and the process repeated until the desired number of lenses or other optical articles such as compact disk substrates are produced.

Reusable vacuum bags are provided which include a fabric layer containing reinforcement fibers and a release surface disposed on at least the first side of the fabric layer. The vacuum bag is capable of withstanding multiple mold cycles of the vacuum of less than ambient pressure without significant leakage. In addition, the described vacuum bag can be used in resin transfer molding and standard bagging operations with commercial benefit.

Simulated stone, masonry, and brick textured products such as siding having a foam backing or with the hollow parts injected with foam or molded with foam in one or more steps, obtained when specially selected materials are properly admixed and formed via molding techniques. The foam backing is applied to the product in either a one or two step process. The foam backing may be used on panels, wall structures, and other products that may have contoured and textured surfaces and may simulate the appearance of conventional building and construction materials including, but not limited to, stone, brick, masonry, concrete, stucco, wood, other conventional building materials, and combinations of any of these materials are disclosed. The foam backing provides improves thermal insulation, improved sound reduction, improved rigidity, and improved dimensional stability. The disclosed invention is not limited to products in the building or construction industries and may be applied in the manufacture of a wide variety of products in other industries.

An interior trim component such as a vehicle dashboard includes a substantially rigid and form-stable substrate of polypropylene and natural fibers, a supporting halo skeleton and other frame components heat fused onto the backside of the substrate, and a polyolefin foam layer as well as a decorative polyolefin cover film laminated onto the front side of the substrate. The foam layer has an increased thickness and a decreased foam density at sharply contoured or curved areas of the trim component, in comparison to the flat surfacial areas. As a result, the trim component has a desirable soft-touch characteristic and impact absorbing properties at all areas including protruding curves and edges. A method for forming such a trim component involves steps of pre-molding the foam layer and cover film by vacuum thermoforming, pre-molding the substrate by vacuum thermoforming, and then heat laminating the pre-heated, pre-molded substrate onto the pre-molded foam layer and cover film. The sharply curved or contoured areas of the component are provided with a greater tolerance spacing between the substrate and the cover film, which are held to the respective mold contours by vacuum. Under the effect of heat and the applied vacuum, the foam layer expands to have a greater thickness and a lower density in these sharply contoured areas.

Disclosed is a light emitting diode (LED) package having multiple molding resins. The LED package includes a pair of lead terminals. At least portions of the pair of lead terminals are embedded in a package main body. The package main body has an opening through which the pair of lead terminals is exposed. An LED die is mounted in the opening and electrically connected to the pair of lead terminals. A first molding resin covers the LED die. A second molding resin with higher hardness than the first molding resin covers the first molding resin. Therefore, stress to be imposed on the LED die can be reduced and the deformation of the molding resins can be prevented.

A system and method for reinforcing at least a portion of a structural member, including at least one hollow carrier, having an exterior shell and an interior portion, which substantially conforms to the dimensions and geometry of the structural member being reinforced; and a lightweight, low density material for filling the interior portion of one or more of the carriers. The material filling one or more of the carriers of the present invention can be a reinforcement material, self-curing material, or a heat activated expandable material. The carrier can be produced by blow molding or rotational molding and has an adhesive material disposed along at least a portion of the exterior shell used to place, adhere, and affix the carrier to a targeted portion of the structural member selected to be structurally reinforced.

A compound mold or tooling system is designed to provide an alternative to conventional, expensive, metal molds for various plastics molding applications. The compound mold comprises a replaceable thin-walled liner, or skin-mold, defining the mold surface, temporarily bonded by vacuum means or mechanical means to a conforming backing-mold mold body supported by a rigid backing-plate. Both skin- and backing-molds are composed of suitable polymers with or without additives, fillers, reinforcements or other inclusions depending on mold requirements. The backing-plate contains standard features and fixtures common to all molds used in the particular process or of a particular geometry.

A device includes a top package bonded to a bottom package. The bottom package includes a molding material, a device die molded in the molding material, a Through Assembly Via (TAV) penetrating through the molding material, and a redistribution line over the device die. The top package includes a discrete passive device packaged therein. The discrete passive device is electrically coupled to the redistribution line.

The crosslinkable rubber composition of the invention is crosslinkable by hot air, and a hot-air crosslinked rubber sheet thereof has no scratch on the surface in a hardness test using a pencil of HB and has a compression set of not more than 70% after a heat treatment at 150° C. for 22 hours. The rubber composition comprises an ethylene/α-olefin/non-conjugated polyene random copolymer rubber comprising a specific vinyl end group-containing norbornene compound, a SiH group-containing compound having at least two SiH groups in one molecule, and if necessary, an addition reaction catalyst comprising a platinum group element and a reaction inhibitor. The automobile weatherstrip, hose, rubber vibration insulator, belt, sealing material, expanded product, covered electric wire, electric wire joint, electric insulating part and household rubber product according to the invention comprise the above-mentioned rubber composition. The rubber composition has a high crosslinking rate and excellent productivity to produce crosslinked rubber molded products, is capable of undergoing hot-air crosslinking such as HAV or UHF and is capable of providing crosslinked rubber molded products having excellent compression set resistance, strength properties, heat resistance, weathering resistance and abrasion resistance.

The present invention relates to cellulose esters having low hydroxyl content for use in optical applications, such as liquid crystal display (LCD) films. Films made with low hydroxyl levels and a given ratio of non-acetyl ester to hydroxyl level have been found to have low intrinsic birefringence. Therefore, these films can be cast, molded, or otherwise oriented without an appreciable birefringence or optical distortion (i.e. retardation). Such features make these films useful in polarizer, protective, and compensator films as well as molded optical parts, such as lenses. Furthermore, it has also been found that resins of the present invention can also be made to have “+C plate” behavior either by melt or solvent based processing, a characteristic which is not typical of cellulose esters. Such +C behavior allows films to be produced having unique compensatory behavior. Other embodiments of the invention relate to methods melt casting films while minimizing birefringence formation. Another embodiment of the invention is directed to films made from the cellulose esters described herein further comprising a plasticizer.