A method of manufacturing a plastic lens includes: a step of putting a first curable composition over a forming surface of a first mold substrate having the forming surface for forming a lens surface; a step of spreading the first curable composition over the entire forming surface by pressing the composition with a film to form a first curable composition layer and separating the film from the first mold substrate by a predetermined distance through the formed first curable composition layer; a step of covering defined surfaces; a step of injecting a second curable composition into a defined location; a step of curing the first curable composition layer and the injected second curable composition; and a step of removing to obtain a plastic lens.

A sold nano- or micro-structured thermoplastic foil including a nano- or micro-structured surface area is produced by providing an extrusion casting roller for an industrial polymer extrusion casting process using a thermoplastic material, applying a nano- or micro-structured surface on the extrusion casting roller, maintaining a temperature of the casting roller below a solidification temperature of the thermoplastic material while the casting roller and the counter roller are rotating, and continuously applying a melt of the thermoplastic material between a counter roller and the casting roller while the casting roller and the counter roller are rotating. A rotational velocity of the casting roller may be 10 meters/minute. The melt of the thermoplastic material is moved between the casting roller and the counter roller while the rollers are rolling, and the melt of the thermoplastic material is solidified upon contact with the casting roller to form the thermoplastic foil.

A composite core material and methods for making same are disclosed herein. The composite core material comprises mineral filler discontinuous portions disposed in a continuous encapsulating resin. Further, the method for forming a composite core material comprises the steps of forming a mixture comprising mineral filler, an encapsulating prepolymer, and a polymerization catalyst; disposing the mixture onto a moving belt; and polymerizing said encapsulating prepolymer to form a composite core material comprising mineral filler discontinuous portions disposed in a continuous encapsulating resin.

A lens comprises an internal cavity structure formed by dissolution of a soluble insert material. The internal soluble material may dissolve through a body of a lens such as a contact lens in order to form the cavity within the contact lens. The cavity within the lens can be shaped in many ways, and corresponds to the shape of the dissolved material, such that many internal cavity shapes can be readily fabricated within the contact lens. The insert can be placed in a mold with a pre-polymer material, and the pre-polymer material cured with the insert placed in the mold to form the lens body. The polymerized polymer may comprise a low expansion polymer in order to inhibit expansion of the lens when hydrated. The polymer may comprise a hydrogel when hydrated. The soft contact lens material comprises a sufficient amount of cross-linking to provide structure to the lens and shape the cavity.

Nanoporous composite separators are disclosed for use in batteries and capacitors comprising a nanoporous inorganic material and an organic polymer material. The inorganic material may comprise Al.sub.2O.sub.3, AlO(OH) or boehmite, AlN, BN, SiN, ZnO, ZrO.sub.2, SiO.sub.2, or combinations thereof. The nanoporous composite separator may have a porosity of between 35-50%. The average pore size of the nanoporous composite separator may be between 10-90 nm. The separator may be formed by coating a substrate with a dispersion including the inorganic material, organic material, and a solvent. Once dried, the coating may be removed from the substrate, thus forming the nanoporous composite separator. A nanoporous composite separator may provide increased thermal conductivity and dimensional stability at temperatures above 200 C. compared to polyolefin separators.

A vehicle interior/trim component configured to support an airbag module is disclosed. The component may comprise a structural substrate with a reinforcement to provide a door/opening for airbag deployment. The reinforcement may comprise a pattern of threads (e.g. top stitch to secure the door and bottom stitch). The reinforcement may comprise threads sewn within and/or pressed into a surface of a substrate/panel. The top stitch thread weight may be greater than that of the bottom stitch. The top stitch may comprise a retaining thread/hinge; the bottom stitch may separate upon deployment. The reinforcement may comprise KEVLAR, aramid, nylon, polyester, thread, ceramic fibers, polymeric fibers, synthetic fibers, etc. The structural substrate may comprise a fiber panel, compression-formed component, generally rigid fiber mat, etc. The component may be formed by injecting resin into a mold to form an ancillary component of a composite structure.

An encapsulation method of electronic components comprises steps as follows: preparing electronic components with cylindrical bodies wherein a cylindrical body has front and rear ends made of metals and a middle end made of ceramics and the front end or the rear end features an outer diameter greater than the middle end of the cylindrical body; preparing a mould consisting of upper and lower moulds; encasing the cylindrical bodies inside the upper and lower moulds, injecting heated and softened protective materials into the mould in which protective materials as protective layers are coated on the cylindrical bodies; injecting the cylindrical bodies removed from the upper and lower moulds into a roller in which excessive protective layers on the front and rear ends of the cylindrical bodies are de-coated.

An electrical wire includes a conductor and an insulating layer that covers the conductor and that is cross-linked. The insulating layer is a cross-linked product of a resin composition including (a) a base polymer containing polyolefin and a compatibilizer, (b) a photoradical generator of 0.5 parts by mass or more and 3 parts by mass or less relative to the 100 parts by mass of the base polymer, and (c) a reactive monomer of 1 part by mass or more and 5 parts by mass or less relative to the 100 parts by mass of the base polymer. A relative dielectric constant of the insulating layer is less than 2.5.

A structural reinforcement for an article including a carrier that includes: (i) a mass of polymeric material having an outer surface; and (is) at least one consolidated fibrous insert having an outer surface and including at least one elongated fiber arrangement having a plurality of ordered fibers arranged in a predetermined manner. The fibrous insert is envisioned to adjoin the mass of the polymeric material in a predetermined location for carrying a predetermined load that is subjected upon the predetermined location (thereby effectively providing localized reinforcement to that predetermined location). The fibrous insert and the mass of polymeric material are of compatible materials, structures or both, for allowing the fibrous insert to be at least partially joined to the mass of the polymeric material. Disposed upon at least a portion of the carrier will be a mass of activatable material.

Described herein is a process for producing polyurethane sandwich moldings including at least one core layer and at least one reinforcing fiber layer, where (i) at least one reinforcing fiber layer is applied onto a core layer and a moisture-curing polyurethane adhesive is applied to a reinforcing fiber layer, (ii) the part from (i) is placed into a mold and pressed in the mold and the moisture-curing polyurethane adhesive is cured, and (iii) the molding from (ii) is removed from the mold and optionally subjected to further operations, where the moisture-curing polyurethane adhesive is applied before or after application of the reinforcing fiber layer onto the at least one core layer and for the curing the moisture-curing polyurethane adhesive is brought into contact with water or with a solution comprising water. Also described herein are a polyurethane sandwich molding obtainable by such a process and a method of using a polyurethane sandwich molding in vehicles.