Other

Patent Holding Company

Design Lab, LLC

John F Murphy

Larry J Winget

Ralph A Beckman

Randolph S Porter

Jason Todd Murar

Henry D Sharpe, Iii

Stephen R Schwartz

Kipp Bradford

Stephen A Schwartz

Robert D Scott

Roseann Radosevich

Gregory L Gerold

Stephanie Janis

Jeffrey C Davis

Robert S Rowley

Timothy B Howell

Roseanne Radosevich

A mold for use in a reaction injection molding method and system to make a reinforced polymeric article having reduced surface defects includes a novel gating system. The mold includes a pair of mold sections which define a closed, article-forming cavity, an injection aperture, and an after-mixer which helps to form a plurality of flow paths which extend downstream from the injection aperture toward the article-forming cavity to further mix a curable, multi-component, reaction fluid mixture including a filler. The flow paths are also at least partially defined by an elongated film gate and an elongated runner which extends along and is in fluid communication with the film gate along substantially the entire length of the film gate. The runner has a closed end and an open end into which a fluid mixture for the article flows for distribution by the runner into the film gate.

Method for making a reinforced, polymeric article in a reaction injection molding system and mold for use therein

A method and system of manufacturing an air bag cover assembly utilizing infrared radiation is disclosed. The assembly includes a front panel, a back plate, a switch and infrared-absorbing material. Initially, the front panel and the back plate are positioned so that inner surfaces of the front panel and the back plate define a switch pocket therebetween. Then the switch is positioned in the switch pocket. Thereafter, infrared radiation is directed at the infrared-absorbing material for a time sufficient to heat the infrared-absorbing material to a desired temperature. The amount of heat applied to the infrared-absorbing material by the infrared radiation is controlled by a controller. Finally, the heated material cools to fixedly secures the back plate to the front panel. The heated material may be forced to flow prior to cooling. In one embodiment, the back plate includes a plurality of spaced holes extending therethrough and wherein the infrared-absorbing material forms a plurality of stakes connected to the inner surface of the front panel and extending through the plurality of spaced holes. The heated infrared-absorbing material forms a plurality of solid connectors after cooling. In another embodiment, the infrared-absorbing material is a heat-activated adhesive and the method further includes applying the heat-activated adhesive to at least one of the inner surfaces of the front panel and the back plate.

Method and system for manufacturing an air bag cover assembly including a switch

A method of making a molded plastic component having enhanced surface finish uses a mold having at least one metal base, a mold cavity, and at least one self-lubricating surface layer which defines the plastic component within the mold cavity. The self-lubricating surface layer includes a porous metallic skin integrally connected to and extending from an interior surface of the at least one metal base and lubricating particles disposed on the skin and in pores of the skin. The lubricating particles are bonded together to form a sealed surface of the at least one self-lubricating surface layer such that the molded plastic component has the enhanced surface finish. The metallic skin includes a plurality of spaced, sinusoidally-shaped projections of autocatalytic nickel alloy. The lubricating particles are preferably submicron-sized particles of low friction fluoropolymers. The mold may be an injection mold, a compression mold, a blow mold or a vacuum mold. When the mold is an injection mold, other parts of the mold such as an ejector pin, a core pin, a cooling line and a resin flow path may also have a substantially identical self-lubricating surface layer integrally formed thereon to provide non-stick surfaces thereof. The plastic component may be made of DYM, ABS, Santoprene&reg;, polypropylene, SMC, TPO, TPU, or other plastic compound.

Method of making a molded plastic component having enhanced surface finish

A molded plastic component having enhanced surface finish is molded within a mold having at least one metal base, a mold cavity, and at least one self-lubricating surface layer which defines the plastic component within the mold cavity. The self-lubricating surface layer includes a porous metallic skin integrally connected to and extending from an interior surface of the at least one metal base and lubricating particles disposed on the skin and in pores of the skin. The lubricating particles are bonded together to form a sealed surface of the at least one self-lubricating surface layer such that the molded plastic component has the enhanced surface finish. The metallic skin includes a plurality of spaced, sinusoidally-shaped projections of autocatalytic nickel alloy. The lubricating particles are preferably submicron-sized particles of low friction fluoropolymers. The mold may be an injection mold, a compression mold, a blow mold or a vacuum mold. When the mold is an injection mold, other parts of the mold such as an ejector pin, a core pin, a cooling line and a resin flow path may also have a substantially identical self-lubricating surface layer integrally formed thereon to provide non-stick surfaces thereof. The plastic component may be made of DYM, ABS, Santoprene&reg;, polypropylene, SMC, TPO, TPU, or other plastic compound.

Molded plastic component having enhanced surface finish

A method and system for bonding plastic parts together utilizing a heat-activated adhesive and at least one infrared lamp are disclosed. The system preferably includes first and second infrared lamps for emitting infrared radiation. A first base section supports a first infrared lamp adjacent the first plastic part and a second base section supports the second infrared lamp adjacent the second plastic part. The system also includes a controller coupled to the first and second infrared lamps for controlling power supplied to the first and second infrared lamps so that the first infrared lamp emits infrared radiation which propagates through the first plastic part and is absorbed by the adhesive and the second infrared lamp emits infrared radiation which propagates through the second plastic part and is absorbed by the adhesive for a time sufficient to heat the adhesive to a desired temperature at which the adhesive is activated.

Method and system for bonding plastic parts together

A hollow plastic article of a one-piece construction formed from a molten plastic resin by a gas-assisted injection molding system wherein the article is designed in such a way that any gas channel read through is hidden at a &ldquo;Class A&rdquo; convex surface thereof. The article includes a hollow body section and a solid wall section which extends downwardly and rearwardly from a front wall of the hollow body section. The solid wall section and the front wall immediately adjacent to the solid wall section define a convex, sink-free, exterior surface of the article to hide any gas channel read through.

Hollow plastic article formed by a gas-assisted injection molding system

A toy figure has a movable mouth coupled to an actuator in the belly area. A speech generator stores sound elements for an entire song, verse, or nursery rhyme. The speech generator is provided with a first track of sequenced sound elements (singing version) that form a song when sequentially generated, and a related second track of a like number of sequenced sound elements (humming version). Sound elements from the first and second tracks are interchangeable at any given point during sequential output thereof. A switch located in the mouth is connected to the speech generator to provide input as to the mouth position, i.e. open or closed. Squeezing the belly of the figure opens the mouth, changing the state of the switch and initiating an output sequence from the speech generator. When the mouth is open, the child is able to easily control the mouth position by varying the pressure on the belly actuator. The speech generator checks the state of the mouth switch at given intervals. If the speech generator senses that the mouth is closed, the speech generator switches tracks to begin output of the next corresponding &ldquo;bumming&rdquo; segment of the song. The speech generator continues to check the state of the switch, and if the switch is then reopened, the toy begins to sing again at the same point within the sequenced output.

Method of generating dual track sounds for an electronic toy

A method and system for bonding plastic parts together utilizing a heat-activated adhesive and at least one infrared lamp are disclosed. The system preferably includes first and second infrared lamps for emitting infrared radiation. A first base section supports a first infrared lamp adjacent the first plastic part and a second base section supports the second infrared lamp adjacent the second plastic part. The system also includes a controller coupled to the first and second infrared lamps for controlling power supplied to the first and second infrared lamps so that the first infrared lamp emits infrared radiation which propagates through the first plastic part and is absorbed by the adhesive and the second infrared lamp emits infrared radiation which propagates through the second plastic part and is absorbed by the adhesive for a time sufficient to heat the adhesive to a desired temperature at which the adhesive is activated. The activated adhesive bonds the plastic parts together. The system further includes first and second blowers coupled to the controller for selectively supplying and interrupting flows of forced air to the first and second parts, respectively, to cool the first and second plastic parts. A temperature sensor is coupled to the controller for sensing the temperature of the adhesive.

A toy figure has a movable mouth coupled to an actuator in the belly area. A speech generator stores sound elements for an entire song, verse, or nursery rhyme. The speech generator is provided with a first track of sequenced sound elements (singing version) that form a song when sequentially generated, and a related second track of a like number of sequenced sound elements (humming version). Sound elements from the first and second tracks are interchangeable at any given point during sequential output thereof A switch located in the mouth is connected to the speech generator to provide input as to the mouth position, i.e. open or closed. Squeezing the belly of the figure opens the mouth, changing the state of the switch and initiating an output sequence from the speech generator. When the mouth is open, the child is able to easily control the mouth position by varying the pressure on the belly actuator. The speech generator checks the state of the mouth switch at given intervals. If the speech generator senses that the mouth is closed, the speech generator switches tracks to begin output of the next corresponding &ldquo;humming&rdquo; segment of the song. The speech generator continues to check the state of the switch, and if the switch is then reopened, the toy begins to sing again at the same point within the sequenced output.

Electronic toy and method of generating dual track sounds for the same

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. Three different embodiments of the gas pin assembly are disclosed.

Mold for use in a gas-assisted injection molding system and gas pin

A toy nursing bottle for use with a doll is provided with a reciprocating nipple that actuates a bellows to create air bubbles in a liquid within the bottle. The toy nursing bottle includes a transparent bottle having a body portion and a neck portion, and a volume of liquid, preferably a colored liquid, in the body portion of the bottle. A resiliently compressible bellows is supported within the neck portion of the bottle. The bellows includes an outlet valve in the bottom wall for injecting air bubbles into the liquid in the bottle when the bottle is inverted and the bellows is compressed, and an inlet valve in the bottom wall for drawing air back into the bellows when the bellows is released. An elongated air inlet tube is connected to the inlet valve and extends upwardly into an air space above the volume of liquid in the bottle so that the air is drawn into the bellows from the air space. A nipple shaped actuator mounted within a cap received on the neck of the bottle has an inner end in engagement with a top wall of the bellows and an outer end extending through the cap for engagement with the mouth of a toy doll. The actuator is reciprocatable axially inwardly for compressing the bellows and injecting air into the liquid within the bottle.

Toy nursing bottle

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. Preferably, the pins are ejector pins and the plate is an ejector plate.

Mold for use in a gas-assisted injection molding system and runner

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.

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.

Growing community of inventors

Imlay City, MI, United States of America

John F Murphy