Abstract: A method for forming complex-shaped sanitary fittings with a mold (10) that includes four parts (11, 12, 13, 14) made of porous resin capable of mutually self-centering by means of complementarily shaped locators (15), in which the method includes the following steps:(a) closing the mold by means of a manual or robotized handling device (23) that has a relatively low force;(b) inserting the closed mold inside a container (16) that has a relatively high force, and generating pressure on six faces of the mold (10);(c) injecting a slip inside the mold (10);(d) extracting the closed mold from the container (16);(e) opening the mold (10).

Abstract: Method and apparatus for forming an article having a prescribed volume and mass from a molten plasticized resin using an injection molding machine by (a) forming an oversized mold cavity with respect to an opposing pair of relatively movable mold members between which the article is formed; (b) injecting into the oversized mold cavity a volume of plasticized resin exceeding the prescribed volume of the article and having a mass at least equal to the prescribed mass of the article; (c) applying force to the mold members to reduce the volume of the cavity and pressurize the plasticized resin therein simultaneously with the injection of resin.

Abstract: A rotationally molded container rim and method for fabrication thereof. The inventive method includes rotationally molding a container while at the same time integrally molding a circumferential rim having an enclosed interior void. Molten plastic and unmelted particles flow from a primary portion of the mold through a gap of uniform width into a secondary mold portion to form the rim. During molding, air is vented from the enclosed void to ambient air outside the mold through a vent opening. The vent opening preferably includes a hollow tube. The rotationally molded container rim that is formed according to the inventive method preferably includes walls that form an enclosed polygonal section. The walls enclose the interior void and at least one vent opening leads from the interior of the rim to the outside of the container.

Abstract: A method is provided for installing a refractory lining in a blast furnace or other metallurgical vessel. A consumable form is installed along an inner surface of an outer shell of the metallurgical vessel. The consumable form is spaced apart from the outer shell. The metallurgical vessel is then filled with burden, which supports the consumable form. Casting composition may then be inserted between the consumable form and the outer shell. The casting composition is heated for a period of time before the burden is ignited. Cables which are lowered from the top of the vessel and secured at a lower end of the vessel may be used. Tubes mounted on panels may be threaded along the cables to position the panels in constructing the consumable form.

Abstract: A method for forming a test specimen from an asphalt concrete mixture includes providing a mold to receive a quantity of the mixture and adding a predetermined quantity of the mixture to the mold. The mixture in the mold is compressed at a pressure of at least about 7 psi while vibrating the mixture in the mold at a rate of at least about 2400 cycles per minute. The method also includes maintaining the vibration of and the application of compressing pressure to the mixture in the mold until the mixture obtains a predetermined mix design density within a range of about 90-97%.

Abstract: Apparatus for injecting grout into a spreader pipe used in the erection of concrete walls. The apparatus has a central jet tube containing holes and having a nozzle locking cap mounted on one end. A jacket containing injection holes encases the jet tube in a manner which covers the holes in the jet tube. The apparatus also contains two draw-in hoses on both sides of the jacket that encases the jet tube. The draw-in hoses operate selectively to bulge out in an axial direction, thereby sealing off an interspace within the spreader pipe between the draw-in hoses and allowing grout to be pumped into the spreader pipe.

Abstract: Parallel spaced grooves are cut within the surface of an existing reinforced concrete member in the direction of bending and at locations where existing tensile reinforcing is inadequate. Elongated reinforcing elements, such as composite rods with continuous carbon fibers, are positioned within the grooves, after a curable bonding material, such as an epoxy resin, is inserted into each groove so that the bonding material surrounds the reinforcing element. The material is formed flush with the surface and allowed to cure to bond each reinforcing element to the concrete defining the corresponding groove. The grooves and reinforcing elements extend within the top surface of a concrete slab across a beam or support for the slab, extend within the bottom surface of the slab at least fifty percent of the distance between adjacent supports for the slab, or within a vertical surface of a concrete or masonry wall or column.

Abstract: A method of making an impeller having inner and outer portions of polyurethane resin having different flexibilities with the outer portion bonded to the inner portion and having greater flexibility than the inner portion, includes rotating a centrifugal casting mold containing a polyurethane resin forming material of predetermined composition, introducing into the inner portion of the mold another polyurethane resin forming composition of different composition than the first material, centrifugal casting the inner and outer portions together, and curing the resulting shape to form a disk having bonded inner and outer portions of polyurethane resin having different flexibilities.

Abstract: A method of forming a patterned wall includes the step of aligning a linear edge of a first linear base form liner with a linear edge of a second linear base form liner to form a non-contoured composite notch surface between a first contoured surface of the first linear base form liner and a second contoured surface of the second linear base form liner. A coupling form liner is then positioned on the non-contoured composite notch surface to produce a continuous pattern between the first contoured surface and the second contoured surface. A mold is then constructed using the first linear base form liner, the second linear base form liner, and the coupling form liner. A hardenable material is then poured into the mold. The mold is removed when the hardenable material has dried to expose a patterned wall.

Abstract: A method of fabricating an ultrasonic coupler to a specified configuration such that the ultrasonic coupler is fabricated by freezing and defrosting an aqueous solution containing a polymer. A surface of the fabricated ultrasonic coupler is made to be smooth. The ultrasonic coupler is fabricated using an ultrasonic coupler fabricating die including members each made of silicone rubber which varies in compliance with the expansion and the contraction of the aqueous solution. To fabricate the ultrasonic coupler, the aqueous solution containing a polyvinyl alcohol (PVA) is poured into the die. Then, the die is subjected to the process of cooling to below the freezing point and the process of recovery to room temperature so as to progress a bridging of the PVA, thereby progressing a gelling of the aqueous solution.

Abstract: A mushroom-type hook strip for a hook-and-loop fastener has a flexible backing of thermoplastic resin and, integral with backing, an array of upstanding stems distributed across at least one face of the backing, each having a mushroom head. The stems have a molecular orientation as evidenced by a birefringence value of at least 0.001. The mushroom-type hook strip can be produced continuously by injecting resin into cavities of a cylindrical mold while evacuating and cooling the cavities so that the cooled resin becomes molecularly oriented, thus affording to the stems excellent stiffness, durability, and tensile and flexural strength.

Abstract: A concrete column forming tube and method of making same for receiving poured concrete column therein to produce a concrete column is characterized by a smooth inside coated surface in the forming tube to eliminate spiral seam lines and other undesirable characteristics on the outside surface of the formed concrete column. The tube is formed from spirally-wound plies of paper adhered together and has a centrifugally-cast epoxy resin coating sprayed onto the inside surface of the spirally-wound tube while the tube is rotating to produce a smooth inside coated surface on the forming tube.

Abstract: The method and apparatus for making a preform which is a rigid shaped item formed of glass fibers rigidly joined to each other where adjacent fibers touch. The interstices between the fibers are unfilled for the use of matrix resin to subsequently form a molded article. The preform is formed by shaping fibers into the preform shape, applying a binder to the fibers so that they are coated at the locations where they touch. The binder is sensitive or responds to the application of electromagnetic energy. In completing the preform after the application of the binder, the preform is subjected to electromagnetic energy so that the binder hardens to form a rigid preform. In one species form, the electromagnetic energy is applied in the form of microwave energy. The application of electromagnetic energy causes a reaction in the binder without requiring heating of the glass fibers so that the preforms can be rigidified rapidly and efficiently.

Abstract: An apparatus for interconnecting form structures, such as formboards and the like, is disclosed which allows for the permanent or removable attachment of a connecting device to the ends of adjacent form structures and which provides for the quick and easy assembly and disassembly of the forms. The connecting device employs opposing connector plates which can be permanently or removably mounted to abutting ends of successive form structures and has a latching device which allows the connector plates to be quickly and easily latched and unlatched for efficient assembly and disassembly of the forming structures.

Abstract: A method and apparatus for fabricating columns, wherein the apparatus includes a column fabricating assembly and a column extractor. The column fabricating assembly includes a unitary column mold and a mold support assembly. The unitary column mold is reusable and is fabricated specially for the task of fabricating a column therein. Uncured column materials are placed into the unitary column mold and the unitary column mold is enclosed in the mold support assembly. The uncured column materials cure, and thus the column is formed, while the unitary column mold is encased in and spun by the mold support assembly. The unitary column mold is removed from the mold support assembly with the column therein. The column extractor is used to extract the column from the unitary column mold; the unitary column mold is secured by the column extractor and the column extractor pulls the column out of the unitary column mold.

Abstract: A method of making a cast concrete stepping stone whose exposed upper surface has the appearance of two or more grouted attractive natural stepping stones. A liquid release agent is applied to the mold which is then placed on a vibrator table and filled with wet concrete. The mold is vibrated for about 30 seconds and the surface of the concrete troweled smooth. Dry body color is sprinkled over the concrete surface and troweled to completely cover the concrete. A dry release agent containing powdered color having a darker shade than the body color is sprinkled over the dry body color covering the concrete. The desired pattern is then pressed into the surface of the concrete and after a six hour drying time, the cast stepping stone is removed from the mold. Excess body color and release agent are washed away and the washed surfaces totally dried. Finally a clear concrete sealer is applied to the exposed upper surface of the concrete stepping stone.

Abstract: Methods of lining the internal surface of a pipe, include first inserting two lining pigs into the pipe and then introducing a batch of resin thereinto, or inserting one lining pig between two batches of a resin, or first inserting a lining pig and then inserting two batches of a resin with another lining pig therebetween, or first introducing a lining pig made of a soft material capable of deforming so as to pass through a narrow-passing section and then introducing a batch of a resin into the pipe, causing the resin to move forward until the front end of the resin reaches an inner end of the pipe, and sucking the resin back from the inner end so as to line the internal surface of the pipe with the resin. The methods use improved liquid blocking pigs for use in pipe lining treatment, each of such pigs includes a spherical body made of a soft resilient material and at least one flexible liquid barrier diaphragm interposed in the spherical body.

Abstract: A patterned shaped article is produced on a given surface by a method including the steps of disposing a partition body on the given surface, temporarily fixing a plurality of cut pattern pieces to the upper surface of the partition body or the upper surface of a mesh member disposed on the partition body so that the cut pattern pieces are disposed adjacent to each other to constitute a pattern to be formed, unfixing one of the cut pattern pieces from a portion of the upper surface to which a pattern-course material is to be supplied, supplying the pattern course material to the portion, repeating the unfixing and supplying steps until the partition body is filled with a prescribed amount of pattern-course materials, removing the partition body alone or together with the mesh member from the pattern-course materials, and allowing the pattern-course materials to set into the patterned shaped article on the given surface.

Abstract: Methods for manufacturing highly insulating connector rods and highly insulating composite wall structures using such connector rods. The connector rods are highly insulating and are injection molded in a single step from an appropriate resinous material or moldable plastic. Discontinuous fibers may be impregnated within the resinous material or other moldable plastic. The single step molding method yields connector rods having pointed ends for facilitating entry through an insulating layer and a first structural layer not yet cured, and also an enlarged head for receiving an impact from a hammer or mallet or for facilitating gripping by the installer. The enlarged head also provides an anchoring effect within a second structural layer upon curing. The connector rods are manufactured to include a ridge or flange to limit the depth of penetration by the connector rod when inserted into the insulating material when forming the composite wall structure.

Abstract: A rigid three-dimensional preform is made by moving a plurality of webs of fibrous reinforcement material superposed and coplanar to a cutter, the webs being coated with an electromagnetic energy-curable binder and pressed together. Prior to cutting a blank in a two-dimensional development of the three-dimensional preform from the webs, the webs are tacked together at spaced local zones by locally curing the binder at those zones by locally applying the appropriate electromagnetic radiation (microwave, ultraviolet, electron) so that the webs travel as one to the cutter. After cutting of the blank, the blank is loaded into a mold to replicate the three-dimensional shape of the preform and the remainder of the binder is cured in the mold by the application of the appropriate electromagnetic radiation.