A molding method includes providing a molding device, wherein the molding device includes a first mold and a second mold corresponding to the first mold; moving the first mold towards the second mold to form a first mold cavity; supplying a gas to the first mold cavity; injecting a material into the first mold cavity; and moving the first mold away from the second mold to form a second mold cavity and discharge at least a portion of the gas out of the molding device, wherein a first volume of the first mold cavity is substantially less than a second volume of the second mold cavity.

A method of forming a cross-car beam is provided. A composite is melted to form a viscous polymer. The polymer is injected into a mold. Pressurized fluid is injected into the mold to evacuate a portion of the viscous polymer from the mold and to form a channel therethrough. The remaining viscous polymer is cooled within the mold to form a cross-car beam.

The invention relates to a method for producing a tube by injection molding a thermoplastic molding compound by using an injection-molding device with an article cavity, which defines the outer contour of the tube, and with an injection device, which is designed to drive a profile through the article cavity filled with the thermoplastic molding compound and thereby displace a liquid core of the molding compound, wherein the method envisages closing an opening of the article cavity with a mould core, which with the article cavity forms a hollow mould space and which has a secondary cavity that can be filled with the molding compound. After the filling of the article cavity and the hollow mould space with the thermoplastic molding compound, a projectile is driven through the article cavity, wherein the projectile displaces the molding compound into the secondary cavity. Subsequently, the mould core with the filled secondary cavity is pulled, wherein the displaced molding compound is separated from the molding compound forming the tube. The invention also relates to an injection-molding device for carrying out the method.

A method of forming a cross-car beam is provided. A composite is melted to form a viscous polymer. The polymer is injected into a mold. Pressurized fluid is injected into the mold to evacuate a portion of the viscous polymer from the mold and to form a channel therethrough. The remaining viscous polymer is cooled within the mold to form a cross-car beam.

A method for the injection molding of internally hollow parts includes the steps of: injecting melt of thermoplastic material in the inner space between a punch and a matrix; opening a valve in order to place the inner space in communication with a secondary compartment; stopping the injection of the melt and opening a valve for supplying nitrogen in the inner space in order to create a cavity within the part being molded; stopping the supply of nitrogen and simultaneous perforation of the part being molded in the section of the connecting duct for the outflow of nitrogen from the mold and the subsequent possible collection thereof; and supplying pressurized air for washing towards the atmosphere after stopping the supply of nitrogen and the simultaneous perforation of the part being molded in the section of the connecting duct.

A method of producing a structure for a component for a vehicle interior may comprise providing a mold with an insert in a cavity, providing resin into the cavity, providing water into the cavity to push a projectile element through the insert into resin in the cavity, pushing the projectile element through the insert and resin across the cavity. The structure may comprise the insert and molded resin. The insert may comprise a metal insert (pipe, tube, etc.). The projectile element may comprise a multi-stage projectile element with a base stage separable from a front stage during forming of the structure. The structure may comprise a second section and a first section with a larger inner diameter than the second section. The insert may be provided in the first section. The base stage may remain in the formed resin structure between the first and second section.

A media channel assembly for an internal combustion engine includes at least one distribution channel for distributing a medium to various components of the internal combustion engine, and at least one supply channel, which is coupled to the distribution channel by way of at least one media passage opening. At least a wall region of the distribution channel lying opposite the media passage opening is curved, at least in parts, toward the media passage opening. An internal combustion engine includes such a media channel assembly, and a motor vehicle includes such an internal combustion engine.

A hollow body molding device forming a hollow molded body in a main cavity of a mold having in its one end a pressure port including a floating core by injecting molten resin through an injection gate into the main cavity having an outlet, and then pressure-injecting pressurized fluid through the pressure port into the main cavity to move the core toward the outlet through the resin injected into the main cavity to extrude the resin through the outlet and discharge it into a waste cavity, the device having: a floating core accommodating portion located between the outlet and a communication passage leading to the waste cavity and adjoins the main cavity and accommodates the core moved to the outlet by the fluid, in the device, a floating core accommodating portion inside diameter is smaller than a main cavity outlet diameter and is larger than a floating core outside diameter.

A method of forming a cross-car beam is provided. A composite is melted to form a viscous polymer. The polymer is injected into a mold. Pressurized fluid is injected into the mold to evacuate a portion of the viscous polymer from the mold and to form a channel therethrough. The remaining viscous polymer is cooled within the mold to form a cross-car beam.

A method produces an injection molded part. A plastic material is injected into a cavity for forming the injection molded part. The plastic material in a flow line region of the cavity, where the plastic material from two directions coincides during an injection molding process, is at least partially removed from the cavity via at least two overflow points and, in so doing, is locally swirled or mixed between the overflow points.