Abstract: The present invention relates to a method for making a prototype by providing at least one polymeric board material having a glass transition temperature less than the molten temperature of a thermoplastic molding material and removing at least a portion of the polymeric board material to form, according to a computer-aided design, a reverse image of a desired article to be molded. Selected molten polymeric molding material is injected into the resulting mold to produce the desired prototype.

Abstract: A mold (100) for producing foamed articles is described. The mold comprises an upper mold and a lower mold (102) releasingly engageable in a closed position to define a mold cavity (106) having a parting line about a periphery of the mold cavity. The parting line of the mold defines: (i) a first channel (108) along a first length of a periphery of the mold cavity, and (ii) a second channel (110) in communication with first channel, the second channel having a second length which is less than the first length. A method for producing a molded article use is also described. The subject mold and method are particularly well suited for the production of molded foam (e.g, polyurethane) articles.

Abstract: A mold for producing a silicon ingot having a layered structure comprising an inner silica layer containing at least one layer in which a fused silica powder with a particle size of 100 &mgr;m or less and a fine fused silica sand with a particle size of 100-300 &mgr;m is bonded with a silica binder, and an outer silica layer containing at least one layer in which a fused silica powder with a particle size of 100 &mgr;m or less and a coarse fused silica sand with a particle size of 500-1500 &mgr;m is bonded with a silica binder.

Abstract: A wax molding toy uses a heat retaining housing with a transparent surface to provide wax melting temperatures with typical indoor solar flux intensities.

Abstract: Use of silicone for the manufacturing of confectionery molds and baking receptacles in general. The silicone may be a heat-curable elastomer of the type intended for applications in contact with foodstuffs, advantageously methyl-vinyl-polysiloxane, and it may be obtained by a process of cross-linking with platinum.

Abstract: An anti-frost concrete mold having an upper frustoconical portion, a transitional shoulder portion and a lower drum portion. The top portion of the mold is adjustable in height. The mold is fabricated simply by molding it over a die. The mold is fabricated from various suitable recycled materials bound with a binding agent.

Abstract: A mold assembly for forming an ophthalmic lens, the mold assembly comprising a first mold and a second mold which cooperate with each other to define therebetween a mold cavity having a profile following that of the ophthalmic lens, wherein the improvement comprises: at least one of the first and second molds being a coated mold consisting of a body portion including a backing surface having rigidity and mechanical strength enough to withstand a molding operation for forming the ophthalmic lens in the mold cavity, and a thermoplastic film retained on the body portion such that the thermoplastic film covers the backing surface of the body portion, the thermoplastic film having a molding surface which partially defines the mold cavity and which gives a corresponding one of opposite surfaces of the ophthalmic lens.

Abstract: The present invention provides a composite molding tool including a surface coat that comprises metal powders and mineral fillers, and a composition comprising a resin mixture and metallic fillers. The composition includes at least about 45% metallic fillers, based on the weight percent of the total composition.

Abstract: Method for on-mold surface coating fiberglass-reinforced molded articles during their manufacture with environmentally friendly and physiologically safe thermosetting unsaturated polyester on-mold coating powders which serve as replacements for liquid gel coats. The thermosetting coating powders employed are adapted to cure at low temperatures to avoid causing thermal damage to the heat sensitive plastic molds which must be reused over and over again, and to cure in the presence of atmospheric oxygen to enable over coating with liquid fill resins and fiberglass, which constitute the bulk of the finished article, without having the fill resins bleed through the powder coating film and detrimentally affect the overall quality of the surface finish.

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 polymer gel is formed into a mold defining a preselected shape. A flowable composition may be formed into a preselected shape via contact with the polymer gel mold.

Abstract: Mold cycle time is accelerated by employing thermally insulating surface temperature boosters, which are of a minimum thickness to promote cooling by heat transfer through the boosters. According to the thermal transfer properties of the insulating boosters and the respective temperatures of the molten material and the dies, the temperature of the cavity surface is raised by contact with the molten material to equal or exceed the temperature required to produce a molded article, preferably just until the time that the mold is fully filled. Heat transfer through the boosters to the dies then cools and solidifies the molded article until it can be removed from the mold. The temperature boosters result in increased cavity surface temperatures, such that the mold dies can be kept at substantially lower temperatures. The overall result is a reduction in mold cooling time and therefore acceleration of mold cycling.

Abstract: Coatings of doped chromium nitride protect forming members such as dies from the corrosive effects of molten aluminum and other reactive metals.

Abstract: A method and system for molding a tissue or substitute tissue product in a mold having an exterior surface, and an interior surface, wherein at least one portion of the interior surface is porous and whose pores are in continuous communication with the exterior surface, and wherein said mold can be fabricated using solid free-form fabrication techniques is disclosed.

Abstract: A method and system for molding a tissue or substitute tissue product in a mold having an exterior surface, and an interior surface, wherein at least one portion of the interior surface is porous and whose pores are in continuous communication with the exterior surface, and wherein said mold can be fabricated using solid free-form fabrication techniques is disclosed.

Abstract: A method of slip casting wherein reduced pressure is applied to the mold during casting by virtue of a network of piping extending through the mold. The mold has an impermeable outer coating. Heat may also be applied to the mold during casting, by for example a heated fluid passing through piping located in the walls of the mold.

Abstract: An RF heating apparatus and method utilizing a mold positioned between a pair of electrodes across which an RF field may be applied to heat working material in a cavity of the mold. The material used to form the mold is selected such that its dielectric constant and parameter of thermosensitivity to an RF field are equivalent the dielectric constant and parameter of thermosensitivity to an RF field of the working material to achieve relatively uniform heating of said working material to a selected temperature. The parameter of thermosensitivity to an RF field of a material generally comprises its power factor divided by the product of its density and specific heat, tan &dgr;/c&rgr;.

Abstract: An assemblage for bonding the skin of an airfoil to the core of the airfoil includes a hybrid caul plate assembly for covering the surface of the airfoil assembly which is exposed to bonding pressure. The hybrid caul plate includes a central elastomeric component and peripheral semi-rigid metal components. The semi-rigid metal components are formed from a steel sinusoidal mesh and are axially elongated. The mesh is flexible in the direction of elongation, but are rigid in the transverse direction. The peripheral semi-rigid caul componnents will thus closely conform to the contours of the core in the axial direction, and will, at the same time, provide support for the edges of the core so that the core edges will not be crushed or deformed by bonding pressure applied to the assemblage during the skin-to-core bonding process. The result of using the hybrid caul plate assembly is an improved skin-to-core bond wherein bridging or voids in the bond line at the periphery of the airfoil are avoided.

Abstract: A mold assembly for molding a thermoplastic resin, which comprises; (a) a first mold member and a second mold member for manufacturing a molded article of a thermoplastic resin, (b) an insert block provided in the first mold member, said insert block constituting part of a cavity, having a thickness of 0.1 mm to 10 mm and being formed of a material having a thermal conductivity of 2.times.10.sup.-2 cal/cm.multidot.sec.multidot..degree.C. or less, and (c) a molten thermoplastic resin introduction portion provided in the second mold member, wherein an insert block covering portion is formed in the second mold member, and when the first mold member and the second mold member are clamped to each other, (A) a clearance between the insert block and the insert block covering portion is equal to, or less than, 0.03 mm, and (B) an amount of overlapping of the insert block and the insert block covering portion is equal to, or greater than, 0.5 mm.

Abstract: A method is disclosed for making a molded refractory article comprising the steps of providing a mold including a molding pattern, the mold and molding pattern defining a mold cavity; filling the mold cavity around the molding pattern with a mixture comprising refractory particles and a heat fugitive binder; inserting a plurality of elements of relatively high melting point material into the mixture to displace a portion of the mixture; curing the mixture; separating the mold and molding pattern from the cured mixture; and sintering the combination of the cured mixture and mixture displacing elements to provide a reinforced molded refractory article. The mixture displacing elements preferably comprise a plurality of parallel tool steel rods. Also disclosed is an apparatus for molding the aforedescribed reinforced refractory article.

Abstract: A method for forming solder bumps on an electronic structure including the steps of first providing a mold made by a sheet of a mold material having a thickness greater than that of the solder bumps to be formed, the mold material has sufficient optical transparency so as to allow the inspection of a solder material subsequently filled into the mold cavities that are formed in the mold material, and a coefficient of thermal expansion that is substantially similar to the substrate which the mold will be mated to, forming a multiplicity of mold cavities in the sheet of mold material, filling the multiplicity of mold cavities with a solder material, cooling the mold to a temperature that is sufficient to solidify the solder material in the multiplicity of mold cavities, positioning the mold intimately with the electronic structure such that the cavities facing the structure, and heating the mold and the structure together to a temperature sufficiently high such that the solder material transfers onto the electro

Abstract: A method for molding an optical disk comprises: applying a thermally insulative insert coating to at least one thermally insulative mold insert to provide at least one coated mold insert having a reduced surface roughness; positioning the coated mold insert between a thermally conductive mold form and a portion of a thermally conductive mold apparatus; injecting a molten thermoplastic material into the mold apparatus; retaining the 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. In another embodiment, the mold insert is coated or laminated on the mold form with the mold insert having a coefficient of thermal expansion compatible with the coefficient of thermal expansion of the mold form. In another embodiment, the mold insert is fabricated by being applied, cured, and then removed from a release layer.

Abstract: A device and apparatus for producing ultra-thin electrophoresis gels formed between spaced-apart plates is provided, where at least one of the plates has a plurality of grooves, the device comprising a spacer comb having extensions formed thereon which are arranged, sized, shaped and located so as to approximately mate with and occupy the grooves on the plate so as to exclude gel material from the grooves during the formation of the electrophoresis gel.

Abstract: Systems are provided to contour hardenable construction material to resemble a natural stone wall. A gang form is provided for molding the natural stone surface having multiple stone regions. The gang form includes a plurality of form liners each including only one lateral relief mold face for contouring a single stone region on the wall formed against the lateral relief mold face. The form liners are mounted to a backing member in an adjacent mating relationship to create a continuous lateral relief mold face.

Abstract: The present invention relates to a mold for a chemically curable composition including a first shell component, a second shell component and a honeycomb core interposed therebetween. The invention further relates to providing an essentially adiabatic environment for chemically cured compositions using the previously described mold.

Abstract: An apparatus and method for molding articles from a fibrous slurry. The apparatus comprises a forming die manufactured from a water insoluble, porous, relatively rigid and easily shaped material having molding surface shaped to the contour of the article to be molded, a vacuum vessel for receiving the forming die, and an opening through the vacuum vessel for communicating with a vacuum means for applying suction through the forming die to draw the slurry against the molding surfaces to form a fiber layer having the configuration of the article to be molded.

Abstract: A gasket defining an axially extending bore therethrough, a front mold having a an edge circumscribing the front mold, wherein the edge is of a size to be complementarily received within at least a portion of the bore of the gasket so that the edge and the bore form a seal therebetween, and a rear mold having a rim circumscribing the rear mold, wherein the rim is sized to be complementarily received within at least a portion of the bore so that the rim and the bore form a seal therebetween. When the front mold and the rear mold are both disposed within the bore of the gasket, a volume is formed between the back surface of the front mold and the front surface of the rear mold and the interior surface of the gasket. A selected one of the front mold or the rear mold is axially and slidably movable within the bore relative to the other mold disposed within the bore to a desired one of a plurality of axial separation distances between the molds, whereby the volume is different for each separation distance.

Abstract: A mold having a cavity for shaping a three-dimensional object, which comprises a photocured resin of a photocurable resin composition comprising(A) a liquid photocurable resin, and(B) at least one reinforcing agent selected from the group consisting of inorganic solid particles having an average particle diameter of 3 to 70 .mu.m and a whisker having an average diameter of 0.3 to 1.0 .mu.m, a length of 10 to 70 .mu.m and an aspect ratio of 10 to 100 and optionally, in which the inner surface of the cavity is covered by a solid film having a thickness of 5 to 1000 .mu.m.

Abstract: A method for preparing a food product to be cooked or reheated in a thermal oven, wherein the food is placed in a container made of a single peeled-wood blank that is folded and assembled at the folded side walls thereof. A tray particularly suitable for use in the method is also disclosed.

Abstract: A mold used for manufacturing an inorganic board and a method of manufacturing an inorganic board by employing said mold are provided in the present invention. Said mold consists of a mold part made of a fiber reinforced plastic and a metal part attached to the back of said mold part, and because of said metal part, the difference in the coefficient of thermal expansion between said mold and an inorganic board manufactured on said mold is small.

Abstract: An injection mold cavity and a method for fabricating an injection mold cavity. The mold cavity includes a tear-drop shaped channel and an ejection valve simultaneously formed with the fabrication of the mold cavity using a layer-additive process. The ejection valve is movable within the mold cavity and actuatable by a flow of gas through the channel to eject a molded part from the injection mold cavity. The mold cavity, including the ejection valve, is made of the same material.

Abstract: A mold assembly for creating a countertop product displaying a built-up edge, the mold assembly having a substantially flat and rectangular planar shaped base which is bounded by first, second, third and fourth interconnected sides to define an interior cavity capable of receiving a pour of a resinous material. A selected number of the interconnected sides, up to all four sides, have inwardly facing surfaces which are configured to produce a countertop product exhibiting a built-up and preferably outwardly bowl-nosed shaped edge. A selectively removable and planar shaped top is arrayed upon the base in overhead fashion relative to the interior cavity and likewise is preferably shaped in a substantially rectangular manner.

Abstract: A molding apparatus for molding an optical component comprises first and second mold sections (20-26, 34) forming opposite sides of a mold cavity (40). The mold cavity has a peripheral edge (43) contacting the optical component during the molding process which is made to reduce the transfer of heat through the peripheral edge (43). In one embodiment of the invention, the peripheral edge is made from a titanium alloy (56) having thermal conductivity approximately 50% of a thermal conductivity of stainless steel. In another embodiment of the invention, the peripheral edge of the mold is made from a porous titanium material (56a) having a density substantially less than the solid titanium alloy. In a further embodiment of the invention, the peripheral edge of the mold is made from a polyimide (70) having oxygen atoms implanted in its surface.

Abstract: In order to produce separate measured portions (1") of liquid solder, solid solder (1) in the form of wire or rod is guided through the longitudinal bore of a guide tube (20). A zone including the end (22) of the tube (20) is heated above the solder's melting temperature, in order to liquefy the solder. By contrast, an adjacent zone of the guide tube is cooled, whereby a positionally stable temperature transition is maintained in the tube (20). Thereby the amount of molten solder available above a narrowed outlet (62) is controlled. A drive mechanism (3) advances the solder (1) step by step so that the solid solder acts as a piston to eject portions of liquid solder through the aforesaid outlet (62). A suitable apparatus (5) for applying portions of solder to a substrate (4) can be raised and lowered (a). At its base it has a moulding die (6) connected to the outlet (62) that can be set down upon the substrate and has a moulding cavity open on its underside.

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: This invention is a paper-based concrete form member and a method for using it. The forms may be made from layers of paper honeycomb material or corrugate. The forms may be structured to be hollow, if so desired. They are principally useful in forming recesses or voids in concrete structures although they may be used to form the edges of concrete products during construction of these products.

Abstract: The present invention is directed to a composition of polystyrene or polypropylene with at least 0.5% (w/w)of an additive or wetting agent, the article of manufacture comprised thereof, such as a mold for making contact lenses and the mold assembly containing said mold, and the use of such mold so to minimize defects, such as holes, puddles, chips and tears in the lens.

Abstract: A mold assembly has a cylindrical inner mold device, and a plurality of outer mold devices enclosing the cylindrical inner mold device. The inner mold device has a threaded interior engaging with a lower portion of a hollow threaded cover and a flange surrounding an outer periphery of the inner mold device. Each of the outer mold devices has a silicone mold and an aluminum mold enclosing an outer periphery of the silicone mold. Each of the silicone mold has at least a pattern cavity. A spacing is defined between the inner mold device and the outer mold devices. An upper annular retainer retains an upper portion of the mold assembly. A lower annular retainer retains a lower portion of the mold assembly.

Abstract: A polymer injection molding unit is disclosed having a mold wall which includes a portion made of an infrared transmissible material which is radiated by an external infrared radiation source. Due to the passage of the infrared radiation through the infrared transmissible material, the infrared radiation is not absorbed by the mold wall and the mold wall is not substantially heated. The infrared radiation passes through the mold wall and is absorbed by the molten polymer material near the mold wall. As a result, the temperature of the molten polymer material rises and its viscosity is lowered to thereby enhance the shape transcription of complicated or fine shapes present on the mold wall, without increasing the temperature of the mold wall.

Abstract: Articles having a diamond-like protective film formed thereon, each comprising a substrate of a material selected from the group consisting of alloys containing at least Co, Ni, or Fe, ceramics, and glass and which has only a slight affinity for a diamond-like thin film, an Mo film formed on the substrate, and a diamond-like thin film formed further thereon. Such articles are manufactured by a method which comprises holding a grid made of Mo close to the surface of the substrate, bombarding the grid and the substrate surface with a bombarding gas consisting of inert gas atoms of Ar or the like, thereby removing contaminants from the surface and depositing Mo atoms on the substrate surface to form an Mo film thereon, ionizing a low-molecular-weight hydrocarbon or a feed gas capable of producing a low-molecular-weight hydrocarbon upon decomposition or reaction, and then accelerating the resulting ions and depositing the same on the Mo film to form a diamond-like film thereon.

Abstract: A concrete form liner includes a microporous membrane having pores that transmit water, but prevent the passage of particles with a diameter of 2 microns or greater, and a porous sheet having pores in the range of 0.2 microns to 60 microns on one side of the microporous membrane, the porous sheet having an air permeability at least five times greater than that of the microporous membrane. The form liner is permeable to air and water in a concrete mix, but is substantially impermeable to cement particles in the concrete mix. A drainage scrim may be juxtaposed against the side of the microporous membrane opposite the porous sheet.

Abstract: The present invention relates to a concrete mold liner and to molds for concrete production which produce patterned or very smooth concrete surfaces.

Abstract: A plastic mold is produced by first repeating the process of forming a layer of a photocurable resin composition of a specified kind and exposing it to actinic radiation to at least partially photocure it to produce a photocured layered structure having a glass transition temperature of 70.degree.-120.degree. C. This structure is then subjected to a post-cure process at a temperature high than the glass transition temperature by 30.degree.-100.degree. C. Plastic molds made by this method have superior heat distortion temperature and tensile elastic modulus.

Abstract: The window buck is made of extruded irregular shapes consisting of a combination of cellulose and polymer compounded specifically to be used in connection with building walls of poured concrete. The combination desirably is a mixture of approximately 70% cellulose and approximately 30% polymer. The cellulose is preferably sawdust, and the polymer preferably is polyethylene.

Abstract: This invention provides a method of molding which can feed the high-viscosity material quickly and accurately as well as with good operability. For achieving quick heating and cooling cycles in a mold, the mold is constructed from a mold material having superior heat-conductivity in such a way that the high-viscosity material can be heated and cooled from outside of the mold.Thereby, this invention comprises:a step for preparing a mold fabricated with high orientation graphite material,a step for feeding high-viscosity material into the recess portion for molding inside said mold in the non-molten state,a step for heating and melting the high-viscosity material in the recess portion via said mold from the outside, anda step for cooling the molten high-viscosity material via said mold and molding it into a desired shape.

Abstract: A elastically and reversibly deformable rubber mold for producing powder compacts is made of a material at least a part of which is a mixture of rubber and magnetic powder. In use, this rubber mold filled with the magnetic powder and subjected to a magnetic field and pressure with punches, thereby compressing the powder to form powder compact. This makes the distribution of magnetic field in the cavity of the rubber mold more homogeneous, and therefore, the distortion, cracking and chipping caused by inhomogeneity of the distribution of the magnetic field are reduced, so that the shape of the resultant powder compact is closer to the end product.

Abstract: A molded fiberglass-reinforced resin boat hull provided with in situ holes to accommodate through-hull fittings, such as a fitting adapted to receive a rudder post. The boat hull is molded on a female mold having locating holes drilled therein in registration with the holes to be formed in the hull. Anchored by a bolt locked in each locating hole is a plug of non-stick material which projects above the mold and has a configuration defining the hole to be formed in situ in the hull. Laid down on the female mold and surrounding the projecting plugs are the reinforcing fiberglass materials and flowable uncured resin for creating the hull. When the resin is cured, it is not bonded to the plugs and the plugs and their anchoring bolts are removed to expose the in situ holes. The finished hull is then withdrawn from the female mold.

Abstract: A method is disclosed for the production of a molded article, using a mold assembly including a mold having a cavity, for producing a molded article from a thermoplastic resin; an insert block formed of ceramic or glass having a thermal conductivity of 2.times.10.sup.-2 cal/cm.sec..degree.C. or less, the insert block being disposed inside the mold, constituting part of the cavity, and having a thickness of 0.5 mm to 10 mm; and a cover plate for covering a peripheral portion of the insert block. The cover plate is attached to the mold and constitutes part of the cavity, wherein a clearance between the insert block and the cover plate is 0.001 mm to 0.03 mm, an amount of overlapping of the insert block and the cover plate is at least 0.1 mm. The method includes filling a molten thermoplastic resin in the cavity, and then cooling the thermoplastic resin to solidness.

Abstract: An insert is described for attachment to a concrete railroad tie mold within an opening formed therein. The insert is adapted to releasably receive and position a railroad rail fastener with a head end positioned below the mold and an anchor part projecting into the mold. The insert includes an insert body including an outward peripheral edge surface shaped to fit within the formed first opening in the railroad tie mold, and an internal peripheral edge surface defining a fastener receiving opening, situated inwardly of the outward peripheral edge surface. The insert body further includes a top surface that is held in substantial coplanar relation to an adjacent mold bottom surface. A clip arrangement provided on the insert body functions to releasably secure the insert body to the mold with the top surface of the insert body being substantially coplanar with the bottom mold wall. An adapter may be provided on the mold to facilitate mounting and positioning of the insert on the mold.

Abstract: A method and apparatus for forming a permanent, composite skin replacement consisting of an epidermal component and a porous, resorbable, biosynthetic laminated dermal membrane component for use in wound repair. The dermal membrane is formed in the apparatus, which permits regulation of variables affecting membrane structure. The dermal membrane may be modified to incorporate biologically active molecules to enhance wound repair and to reduce infection when the skin replacement is applied to a wound.