Abstract: According to the present invention, there is provided a mold constituted by an electrically conductive thin plate having a predetermined surface shape, and an electrically insulating reinforcement material, wherein the electrically conductive thin plate and the electrically insulating reinforcement material are bonded to each other by an anodic bonding method. Particularly, the electrically conductive thin plate is preferably formed out of silicon single crystalline and the electrically insulating reinforcement material is preferably oxide glass.

Abstract: A flange is provided for aligning an injection molding nozzle with a mold gate and insulating the injection molding nozzle from a mold plate. The flange is separate from the nozzle and is releasably connected to a body of the nozzle adjacent to a nozzle head. When the flange and nozzle are coupled, they can be inserted into and removed from a nozzle recess included within the mold plate as a unit.

Abstract: Hybrid molds for molding a multiplicity of solder balls for use in a molten solder screening process and methods for preparing such molds are disclosed. A method for forming the multiplicity of cavities in a pyramidal shape by anisotropically etching a crystalline silicon substrate along a specific crystallographic plane is utilized to form a crystalline silicon face plate used in the present invention hybrid mold. In a preferred embodiment, a silicon face plate is bonded to a borosilicate glass backing plate by adhesive means in a method that ensures coplanarity is achieved between the top surfaces of the silicon face plate and the glass backing plate. In an alternate embodiment, an additional glass frame is used for bonding a silicon face plate to a glass backing plate, again with ensured coplanarity between the top surfaces of the silicon face plate and the glass frame. In a second alternate embodiment, a silicon face plate is encased in an extender material which may be borosilicate glass or a polymer.

Abstract: A resin mold material includes a number of one-dimensional communicating holes extending substantially linearly from a mold surface toward inside and having diameter from 1 nm order to 100 nm order; a surface layer including the mold surface and the one-dimensional communicating holes; a support layer covering a back of the surface, layer; and a number of three-dimensional communicating holes provided to communicate to the one-dimensional communicating holes in the support layer and having 1 &mgr;m order diameter. Accordingly, a liquid resin is unlikely to enter the one-dimensional communicating holes, thereby reducing contact area of the mold surface and the liquid resin, i.e., the mold surface being repellant to the liquid resin. Gas in a cavity is discharged through the one-dimensional and three-dimensional communicating holes sequentially. Consequently, release property of a molded product from the mold surface is improved and generation of voids is suppressed.

Abstract: The present invention relates to elastomeric contact masks, and methods of making these contact masks by complementary molding using complementary molds. The contact masks are made of polymer gels, including hydrogel materials. The complementary molds of the present invention include at least one elastomeric half mold. Also disclosed are methods of continuous complementary molding.

Abstract: A shape memory polymer contact lens mold is formed from a sheet of a shape memory polymer in a press, an agile tool or by an agile tool formed by an inert gas at a temperature at or above the glass transition temperature which is thereupon cooled to below the glass transition temperature and removed therefrom.

Abstract: There are currently milling machines in dental laboratories that take blank blocks of ceramic and mill them into replacement teeth based upon CAD specifications. However, no option currently exists to make the replacement teeth out of anything but ceramic. Thus, I have invented a molded form to make composite blank blocks which are less expensive than ceramic blocks and thus offer an option for the patient.

Abstract: Lay-up mold comprising a contoured metal frame having an overlying conformal coating of polyurethane.

Abstract: Non-stick mold, tool or apparatus is used to convert a liquid or semi-solid material to an end product after the application of a predetermined temperature for a predetermined time. The non-stick mold, tool or apparatus includes a planar portion having at least one cavity. The cavity defined by a side wall that extends downwardly from the planar portion to a closed end. The non-stick mold, tool or apparatus is made from a blend of a fluoropolymer component and a food grade silicon rubber component.

Abstract: A mold used to form a magnetic member includes a mold body having a mold opening, a mold support that supports the mold cavity, and a mold insert. The mold insert is disposed in the mold opening of the mold body to form a mold cavity. The mold insert is coated with a coating to protect the mold body from chemical attack and abrasive wear of the mold material. The coating comprises an electroless nickel layer formed on or over the mold insert, and a chromium nitride layer formed on or over the electroless nickel layer. The mold insert can be formed of beryllium-copper (Be—Cu).

Abstract: An improved screen tooling for a fiber preforming process, and a durable coating system for such tooling. The coating system comprises a surface layer of a porcelain enamel composition that is generally a borosilicate glass, and preferable contains quartz, borax, boric oxide, potassium nitrate, sodium silicofluoride, and manganese dioxide, and optionally contains titanium dioxide, antimony oxide, cobalt oxide and/or barium oxide. Preferred compositions are dependent in part on the screen tooling material. The invention also encompasses a fiber preforming process that utilizes screen tooling with the coating system.

Abstract: A system and method for forming a polymeric molding. A mold component includes a UV-absorptive material for preventing undesired reflection or transmission of curing energy within the mold cavity, thereby providing more precise control of the edge geometry of the molding.

Abstract: A telescoping form for forming a void in poured concrete is disclosed. The form has an upper section defined by a plurality of sides, the upper section of plastic composition, and a lower section capable of telescoping into the upper section, the lower section of plastic composition. The telescoping form may be permanent. The telescoping form may have a lid removably mounted to the upper section of the form.

Abstract: An apparatus is provided for producing a substrate for PDP, which can easily reduce ununiformity of a dielectric layer and defects of ribs.

Abstract: A method and mold assembly to control the polymerization of a cast optical device. The mold assembly includes at least one mold portion having a non-critical surface with fresnel or diffractive geometry. Alternately, a fresnel lens or diffractive lens may be placed at a predetermined distance from the mold.

Abstract: Two molds (102, 104) are provided formed of semiconductor material. The molds (102, 104) have substantially planar working faces (108, 110) into which recesses (106, 112) are formed. In use the molds (102, 104) are pressed together with the working faces (108, 110) opposed so the recesses (106, 112) form mold cavities. The molds (102, 104) only contact each other in the plane of the working faces (108, 110).

Abstract: A rustication for preparing reveal bands in a precast panel surface. The rustication is made from a one piece elongate body of extruded foam and comprises an upper surface, a lower surface and laterally-spaced sidewall surfaces that extend between the upper and lower surfaces. The lower surface defines a base plane. One or more downward-extending edges that project below the lower surface base plane are included such that they can bend under the application of a load, such as when concrete is poured around it to form the precast panel. Under such a load, the edge scrapes along the top of a panel-forming surface so that an enhanced sealing engagement between the panel-forming surface and the rustication is effected. The rustication can further include a plurality of longitudinally-spaced apertures that extend from the upper surface to the lower surface to facilitate the securing of the rustication to the panel-forming surface, thereby precluding rustication shift once the concrete is pouted.

Abstract: A method of cast molding an intraocular implant from two or more dissimilar materials using disposable molds. The subject cast molding method is particularly useful in the production of intraocular lenses manufactured from dissimilar materials. It is desirable to produce intraocular lenses from dissimilar materials in order to optimize the optical characteristics of the intraocular lens optic portion and to optimize stability and flexibility characteristics of the intraocular lens haptic elements.

Abstract: This invention describes molds made from alicyclic co-polymers that are useful in the production of contact lenses and methods for their use.

Abstract: The invention concerns a method and a moulding device in which an inner liner of a fluoroplastic foil in a vacuum infusion moulding or vacuum assisted pressure process for the manufacture of fibre reinforced composite products in Resin Transfer Moulding (RTM) process. By the method and the moulding device, a simple closed moulding technique is provided, which is cost efficient, as the backing foil is reusable.

Abstract: An anti-reflection molding has a transparent substrate (1) and an anti-reflection layer (5) provided at least on a surface of the transparent substrate (1), an interface of a transparent window on which the anti-reflection layer is formed has an average surface roughness Ra of between 2.0 and 150 nm, and the molding has a curved surface having a radius of curvature of not less than 40 mm and protruding on the surface side or a flat surface in the transparent window.

Abstract: The invention relates to a method and system for producing verified component designs and for assisting in tool design to near-production specification in the materials of choice, via production processes and in considerably shorter time scales than has previously been possible.

Abstract: A mold for a microlens includes a substrate at least a portion of which is electrically conductive, such as an electrically-conductive substrate or a substrate with an electrode layer, an insulating mask layer formed on the substrate and including an opening or plural openings, and a plated layer electroplated in the opening and on the mask layer. A first condition that a diameter or width (&phgr;) of the opening has a relation of &phgr;≦0.35R, wherein (R) is a radius of curvature of the plated layer right above the opening, or a second condition that the diameter or width (&phgr;) of the opening is &phgr;≦10 &mgr;m, is met.

Abstract: A method for annealing a structure formed by electrodeposition is provided, the method comprising providing the electrodeposition structure, the electrodeposition structure comprising an electroformed mold, the electroformed mold having a nominal thickness between and including 0.5 mm to 8.0 mm and having a melting temperature; heating the electrodeposition structure to a temperature between ambient temperature and the melting temperature of the electrodeposition structure; isostatically pressurizing the electrodeposition structure to a pressure above ambient pressure; cooling the electrodeposition structure to ambient temperature; and depressurizing the electrodeposition structure to ambient pressure.

Abstract: An injection mold insert and a method of fabricating an injection mold insert for molding lens molds which provides a plurality of replicates of a single master mold mandrel which may be produced, for example, by diamond point. The mandrel is used to electroform an electroform mold insert component having an optical quality surface which forms a surface of an injection mold. An adhesive is used to fixedly attach the electroform mold insert to a separately machined mold insert substrate.

Abstract: A method of replicating a structured surface that includes providing a tool having a structured surface having a surface morphology of a crystallized vapor deposited material; and replicating the structured surface of the tool to form a replicated article. A replicated article includes at least one replicated surface, wherein the replicated surface includes a replica of a crystallized vapor deposited material. A replication tool includes: a tool body that includes a tooling surface; and a structured surface on the tooling surface, wherein the structured surface includes crystallized vapor deposited material or a replica of crystallized vapor deposited material.

Abstract: A method for producing an aspherical structure according to the invention includes the steps of: forming a layer on a surface of a substrate so that the layer exhibits an etching rate distribution in a direction perpendicular to the surface of the substrate; forming a mask having a predetermined opening shape on the surface of the layer; and etching the layer to thereby form at least one aspherical concave portion. When each concave portion is used as a molding tool so that a resin with which the concave portion is filled is solidified and removed from the concave portions an aspherical lens array can be formed accurately.

Abstract: A molding device has a first outer mold, a second outer mold engaging with the first outer mold, a silicon mold disposed between the first outer mold and the second outer mold, a center mold, an upper ring, and a lower seat. The first outer mold has a first inner thread, a first upper flange, a first upper inner groove, a first middle flange, a first lower flange, a first bottom base, and a first lower inner groove. The second outer mold has a second inner thread, a second upper flange, a second upper inner groove, a second middle flange, a second lower flange, a second bottom base, and a second lower inner groove. The lower seat is inserted in the first lower inner groove of the first outer mold and the second lower inner groove of the second outer mold. The center mold passes through the upper ring and the silicon mold.

Abstract: A method of making precision geometry honeycomb material formed of a composite material and exhibiting dimensional uniformity, is disclosed. Composite material is molded in the cavity of a single-sided female mold to form a first web with a plurality of honeycomb cell portions of the desired cell shape in the web. The details of the cavity mold configuration are captured to form the honeycomb cell portions in the composite material during molding the web by applying pressure to the composite material in the mold with an elastomeric pressure intensifier. The composite material of the web is stabilized as by curing. First and second molded webs are precisely aligned in a fixture and joined together at facing cell nodes thereof by bonding yielding a honeycomb material with superior geometric platform.

Abstract: This invention relates to the preparation of molds for the production of contact lenses and other ophthalmic articles. By using an inorganic material to coat the optical surfaces and sidewalls of mold parts made from clear-resin materials, manufacturers can produce lens molds with greater dimensional stability and chemical resistance. In addition to protecting the clear resin from interaction with otherwise reactive monomers from which the molded article is made, such coatings can also be used to achieve preferential release of the molded article. The resulting mold is especially useful for providing an economical way to improve manufacturing quality of contact lenses.

Abstract: A method for preparing a mold form includes forming a mold blank having a surface corresponding to the surface of the article desired and enclosing the mold blank in an open ended enclosure. A thin layer of polymer resin, preferably polyurea is sprayed on the surface of the mold blank and allowed to cure. Heat transfer tubing is inserted over the resin layer. A mixture of metallic pellets and epoxy are inserted over the heat transfer tubing and then another layer of resin is sprayed over the mixture. After the resin has cured, the mold blank is removed to expose the mold form having an outer surface of polyurea.

Abstract: This invention relates to a flexible mould made of silicone for confectionery, bread-making or similar, particularly suited to the use both in traditional ovens and microwave ovens, consisting of a tray provided, on the upper side, with an edge which estends outwardly, wherein this edge is equipped with a support and stiffening element, preferably consisting of a metallic wire dippen in the silicone or of platic or metallic frame partially co-stamped at sight, or manually inserted into a corresponding seat provided in the edge.

Abstract: Non-stick mold, tool or apparatus is used to convert a liquid or semi-solid material to an end product after the application of a predetermined temperature for a predetermined time. The non-stick mold, tool or apparatus includes a planar portion having at least one cavity. The cavity defined by a side wall that extends downwardly from the planar portion to a closed end. The non-stick mold, tool or apparatus is made from a blend of a fluoropolymer component and a food grade silicon rubber component.

Abstract: A polymer mixture, a mold design including a porous steel part and a process for producing a one piece polymer hypodermic tip having a stiff needle part of uniform small diameter and a length exceeding 0.4 inches.

Abstract: A sol-gel process for producing dry porous gel monoliths, e.g., silica glass monoliths, in which the successive process steps of gelling, aging and drying all occur within a mold formed of a selected porous material, e.g., graphite. The mold is inert to the gel solution and it has sufficient strength to withstand the temperatures and pressures encountered during the process. The mold and gel thereby can remain within a sealed autoclave during these process steps, and mechanical handling of the mold and the gel are minimized. This substantially enhances the process' efficiency. Alternatively, the mold can have a non-porous inner skin to enhance ease of cleaning of the mold, and of removal of the gel.

Abstract: A resinous die for press-shaping a blank material into a desired configuration, which comprises a die member and a mating punch, both having respective shaping portions. Each shaping portion is formed of an epoxy resin layer provided at portions thereof where a relatively low surface pressure is applied, and a plurality of reinforcing pieces provided in an embedded fashion at portions thereof where a relatively high surface pressure is applied, for reinforcing the shaping portion. This arrangement imparts increased durability to the shaping portion and hence the die while keeping the cost of manufacture of the die to a minimum.

Abstract: A method for molding an optical disk includes applying a thermally insulative mold insert onto a thermally conductive mold form by coating the mold insert on the mold form. The mold insert has a coefficient of thermal expansion compatible with the coefficient of thermal expansion of the mold form and includes an adhesion promoting material. The method further includes positioning the coated mold form in a thermally conductive mold apparatus with the mold insert positioned between the mold form and the mold apparatus; injecting a molten thermoplastic material into the mold apparatus; retaining the molten thermoplastic material in the mold apparatus for a time sufficient for the molten thermoplastic material to cool below its glass transition temperature to form the optical disk; and ejecting the optical disk from the mold apparatus.

Abstract: A mold for molding a core for use in casting hollow parts includes, a lower mold portion and an upper mold portion defining therein a cavity corresponding to the outer surface of the core. The lower mold portion includes a cutout disposed along a parting line defined between the lower mold portion and the upper mold portion and opening onto the cavity. After introduction of a ceramic slurry mixture into the mold the upper mold portion is removable, to expose a first side of the core and a protective flash formed in the cutout. Desirably, a heat shield is positioned over the protective flash and the exposed portion of the parting line of the lower mold portion so that the lower mold portion is not exposed directly to a flame during a preliminary firing to impart sufficient strength to the ceramic core so that the ceramic core may be handled.

Abstract: A system to fabricate precise, high aspect ratio polymeric molds by photolithograpic process is described. The molds for producing micro-scale parts from engineering materials by the LIGA process. The invention is a developer system for developing a PMMA photoresist having exposed patterns comprising features having both very small sizes, and very high aspect ratios between part minimum feature size and part overall dimension. The developer system of the present invention comprises a developer tank, an intermediate rinse tank and a final rinse tank, each tank having a source of high frequency sonic agitation, temperature control, and continuous filtration.

Abstract: In a method of manufacturing a mold for forming an information pattern including servo information or address information on a substrate of a recording medium by being pressed onto the heated substrate, carbon is used as a material for the mold. A mask corresponding to the information pattern is formed on the mold made from carbon of the present invention. Said carbon plate is etched in areas having no mask formed thereon, and lastly the mask is removed.

Abstract: This invention offers the new molds assembly structure for a plastic art, which enables the both of the complicated design molding process and low material cost of the mold for mass-production by applying the inner silicone rubber portion and the outer plaster portion.

Abstract: The invention relates to a method of producing a matrix suitable for use in a plastic element-producing machine, a matrix produced in accordance with the method and use of such a matrix to form a plastic element. One side of the matrix is provided with a negative microstructure which is replicated in plastic material to form a positive microstructure on a plastic element, wherewith the matrix can be produced by applying a layer of material to the positive microstructure side of a master. The positive microstructure side of the master has a thin wear-resistant layer which serves as a first wear surface, wherewith said layer will present irregularities which correspond essentially to the microstructure, and wherein at least said irregularities are filled-in with a plastic composite so as to form a carrier element for supporting the first wear layer. The layer can further be provided with means for supplying heat energy to said matrix.

Abstract: Hybrid molds for molding a multiplicity of solder balls for use in a molten solder screening process and methods for preparing such molds are disclosed. A method for forming the multiplicity of cavities in a pyramidal shape by anisotropically etching a crystalline silicon substrate along a specific crystallographic plane is utilized to form a crystalline silicon face plate used in the present invention hybrid mold. In a preferred embodiment, a silicon face plate is bonded to a borosilicate glass backing plate by adhesive means in a method that ensures coplanarity is achieved between the top surfaces of the silicon face plate and the glass backing plate. In an alternate embodiment, an additional glass frame is used for bonding a silicon face plate to a glass backing plate, again with ensured coplanarity between the top surfaces of the silicon face plate and the glass frame. In a second alternate embodiment, a silicon face plate is encased in an extender material which may be borosilicate glass or a polymer.

Abstract: A sacrificial plastic mold having an electroplatable backing is provided. One embodiment consists of the infusion of a softened or molten thermoplastic through a porous metal substrate (sheet, screen, mesh or foam) and into the features of a micro-scale molding tool contacting the porous metal substrate. Upon demolding, the porous metal substrate will be embedded within the thermoplastic and will project a plastic structure with features determined by the mold tool. This plastic structure, in turn, provides a sacrificial plastic mold mechanically bonded to the porous metal substrate which provides a conducting support suitable for electroplating either contiguous or non-contiguous metal replicates. After electroplating and lapping, the sacrificial plastic can be dissolved to leave the desired metal structure bonded to the porous metal substrate. Optionally, the electroplated structures may be debonded from the porous substrate by selective dissolution of the porous substrate or a coating thereon.

Abstract: Replicas are molded by curing a photo-curable liquid silicone rubber composition to form a transparent mother mold having a cavity corresponding to the outer contour of a master model, casting a photo-curable liquid resin into the mold cavity, and irradiating light to the liquid resin through the mold wall. Replicas can be fabricated by simple steps and within a short time.

Abstract: A process for producing inorganic molds involving molding a kneaded mixture containing a particulate inorganic material and water, which process comprises adding water-soluble hemicellulose to the kneaded mixture. The process provides inorganic molds with excellent dispersion stability of the inorganic material particles and improved plasticity, workability including fillability and shape retention, as well as strength.

Abstract: According to the present invention, there is provided a mold constituted by an electrically conductive thin plate having a predetermined surface shape, and an electrically insulating reinforcement material, wherein the electrically conductive thin plate and the electrically insulating reinforcement material are bonded to each other by an anodic bonding method. Particularly, the electrically conductive thin plate is preferably formed out of silicon single crystalline and the electrically insulating reinforcement material is preferably oxide glass.

Abstract: A sacrificial plastic mold having an electroplatable backing is provided. One embodiment consists of the infusion of a softened or molten thermoplastic through a porous metal substrate (sheet, screen, mesh or foam) and into the features of a microscale molding tool contacting the porous metal substrate. Upon demolding, the porous metal substrate will be embedded within the thermoplastic and will project a plastic structure with features determined by the mold tool. This plastic structure, in turn, provides a sacrificial plastic mold mechanically bonded to the porous metal substrate which provides a conducting support suitable for electroplating either contiguous or non-contiguous metal replicates. After electroplating and lapping, the sacrificial plastic can be dissolved to leave the desired metal structure bonded to the porous metal substrate. Optionally, the electroplated structures may be debonded from the porous substrate by selective dissolution of the porous substrate or a coating thereon.

Abstract: A mold assembly for forming an ophthalmic lens, or a lens blank from which one ophthalmic lens is produced by effecting a cutting operation on at least one of a front surface and a back surface of the lens blank, the mold assembly consisting of a first mold having a molding surface and a second mold having a molding surface, which first and second molds are assembled together so as to define therebetween a mold cavity having a profile corresponding to that of the ophthalmic lens or the lens blank, the mold cavity being filled with a polymeric material which is polymerized to form the ophthalmic lens or the lens blank, wherein at least one of the first and second molds is a layered mold which is constituted by a composite sheet comprising a metal sheet layer and at least one resin layer which are laminated on each other, the at least one resin layer of the composite sheet providing the molding surface of the layered mold which partially defines the mold cavity.

Abstract: Hybrid molds for molding a multiplicity of solder balls for use in a molten solder screening process and methods for preparing such molds are disclosed. A method for forming the multiplicity of cavities in a pyramidal shape by anisotropically etching a crystalline silicon substrate along a specific crystallographic plane is utilized to form a crystalline silicon face plate used in the present invention hybrid mold. In a preferred embodiment, a silicon face plate is bonded to a borosilicate glass backing plate by adhesive means in a method that ensures coplanarity is achieved between the top surfaces of the silicon face plate and the glass backing plate. In an alternate embodiment, an additional glass frame is used for bonding a silicon face plate to a glass backing plate, again with ensured coplanarity between the top surfaces of the silicon face plate and the glass frame. In a second alternate embodiment, a silicon face plate is encased in an extender material which may be borosilicate glass or a polymer.