Abstract: A divisible slip-casting mold has filter layers which incorporate a combination of different types of fluid-flow conduits to achieve improved fluid-flow properties. The conduits include major portions of porous ropes arranged in curved lines and minor portions of blind holes installed in straight lines. The porous ropes are essentially installed in those portions of the filter layer where the ropes are readily or uniformly arranged, and the blind holes are essentially installed in those portions of the filter layer which exhibit poor fluid-flow properties and in which installation of porous ropes is difficult. Thus, substantially uniform fluid-flow properties are provided in the filter layers of the mold to enhance mold casting performance.

Abstract: A process for producing a molded article is provided includinga) The surface of a mold is cooled with a releasing agent for powder molding which has, as an essential component, a copolymer AB derived from at least one monomer A represented by the following general formula (I) ##STR1## wherein X is a hydrogen atom or a methyl group, k is an integer of 0-5, l is an integer of 1-3, m is an integer of 1-3, n is an integer of 0-550 and Y is a methyl group or a fluorine atom-containing substituent having 1-20 carbon atoms,and at least one vinyl-polymerizable monomer B containing at least one alkyl acrylate or alkylmethacrylate wherein the alkyl group has 1 to 8 carbon atoms.b) The coated mold is heated.c) A powder of a non-rigid vinyl chloride resin containing a plasticizer is allowed to adhere to the heated mold to melt the powder.d) The mold, releasing agent and powder are cooled to form a molded article.e) The molded article is peeled from the mold.

Abstract: A pressurized slurry casting machine is provided which includes a feed tank with an agitator, a vertical conduit extending from the feed tank to a mold. The machine operates by creating pressure in the feed tank with the agitator propeller whereby the ceramic slurry will be forced to move up the straight conduit into the mold so as to be formed into the desired article. The respective connections of the conduit to the mold and the feed tank are each air-tight connections such that no air bubble-like contamination will result in the finished ceramic product. There is also provided a vacuum system capable of producing a negative pressure in the feed tank.

Abstract: Novel processes have been developed by the present invention for producing hollow ceramic articles. Such ceramic articles are produced by using a water-absorbable mold having water non-permeable faces on an inner surface of the mold at locations corresponding to valve holes. The thickness of a ceramic layer deposited on the inner surface of the mold is controlled by measuring an amount of a lowered liquid surface level of the slurry near a slurry-pouring opening of the mold. Open ends of a hollow ceramic article are formed by cutting corresponding closed ends after deposition of the slurry and firing. A uniform thickness of a slurry deposited onto the inner surface of the mold can be attained by rotating the mold around an arbitrary rotary axis at a rotation speed of 1 to 60 rpm. All ceramic material contained in the slurry fed inside the mold may be deposited on the inner surface of the mold while the mold is being rotated or swung.

Abstract: A skin or shell for use in a mold process in which the skin or shell is placed in a mold in which foam precursors are directed onto the skin for reaction thereagainst to form a foam layer thereon; the skin includes integral connector features thereon adapted to be connected to the mold for stabilizing the location of the skin within the mold so as to prevent wrinkling of the skin during the mold process.

Abstract: A solution containing polymerizable monomers and volatile solvents can be used to disperse ceramic particles along with ceramic whiskers and remain pourable even with high solids. Using this dispersion, a high solids ceramic article can be molded, polymerized in situ and fired with a good binder burnout.

Abstract: An apparatus for pressure molding ceramic articles includes at least one split mold including a core mold and an outer mold which are joined together for defining a pressure mold cavity therebetween. At least the bottom surface of the pressure mold cavity is inclined longitudinally and laterally, while the split mold per se is not inclined and the slip supply passage for supplying the slip into the pressure mold cavity communicates with the lowermost end of the pressure mold cavity. Due to the above construction, it is no longer necessary to incline the entirety of the split molds so that the frame structure of the apparatus can be vertically constructed on a horizontal floor which permits easy construction installation and adjustment and maintenance of the apparatus. Furthermore, since the bottom surface of the pressure mold cavity is inclined longitudinally and laterally, the surplus slip is discharged completely and smoothly, and does not remain in the pressure mold cavity.

Abstract: A slush molding method including the steps of preparing a mold with a groove provided on the entire periphery of the opening portion thereof, engaging a heating medium guard frame with the groove, charging a resin material into the mold, heating the mold into the heating medium which is contained in a fluidized-bed oven and fluidized by air so as to melt the resin and cause it to adhere to the molding surface and removing the heating medium guard frame to discharge the surplus resin. An apparatus used for the slush molding method is also included.

Abstract: A process for forming a multi-colored integral vinyl skin shell including a heated mold and dual powder box arrangement wherein the mold is formed to include alternately positioned tear surfaces and recessed surfaces. After the first powder box supplies a layer of powder to cover all the surfaces to form a shell, the strips of shell on the tear surfaces are removed, after which the first powder box is replaced by a second powder box. The second powder box has a plurality of spaced dams or dividers formed therein such that the dams cooperate with the respective recessed surfaces of the mold to provide clearances therewith that permit different colored powders in the compartments between the dams to cover the previously cleared tear surfaces and to flow past the selectively formed free ends of the dams to become integrally secured to the adjacent edge portions of the shell segments remaining in the areas of the recessed surfaces of the mold, forming the multi-colored, integral plastic shell.

Abstract: A method of forming a slush mold and a synthetic resin skin utilizing the slush mold. The method includes the steps of roughing a foamed synthetic resin surface to define a prototype having a plurality of irregularly spaced and irregularly sized recesses, forming a metal mold to have a molding surface accurately complementary to the prototype surface and molding a skin of synthetic resin against the molding surface of the metal mold. The recesses preferably have a cross section dimension in the range of approximately 170 to 500 microns and a depth in the range of approximately 8 to 133 microns. Narrower preferred ranges are disclosed. The surface preferably has a regular unbiased variance of less than approximately 300 microns and preferably less than 200 microns.

Abstract: A process for molding plastic parts includes the steps of providing two or more colors of pigmented powder particles of thermoplastic material; casting the particles against a heated surface to form non-patterned layers of particles with voids therebetween; heating the layers to form color blended fused fringe zones between the particles which fill the voids to form a solid, multi-colored, three-dimensional article while each particle retains its discrete particle core which maintains each particle's central or original color concentration and which cores have discernible light transmissive properties.

Abstract: Fogging of plastics containing polymer plasticizers is reduced by treating the polymer plasticizers with water vapor in the melt.

Abstract: A method and apparatus for the production of a synthetic resin skin uses a mold for forming at least two separate skin sections which are then joined prior or after a final heat treatment. The synthetic resin skin sections are produced in at least two separate mold members, and the skin sections are then caused to contact each other along determined faces or margins which are joined under light pressure. Any so-called selvage is easily removed after the joining which intimately bonds the skin sections to each other due to the curing of the synthetic resin.

Abstract: A method is provided for producing an integral skin foam article made up of a skin, foam and core member. According to the method, an expanded layer which is of the same material as the skin is formed on the back of the skin prior to forming the article.

Abstract: A rotational molding process for slush casting mold with plastisol includes providing a conveyor having a plurality of spaced reversing arm assemblies, each arm assembly having opposite ends carrying molds thereon; providing first and second conveyor paths for the molds on the opposite ends of each arm assembly and locating one of the first and second conveyor paths inside the outer perimeter of the other of the first and second conveyor paths; preheating a mold on one of the arm assemblies on the first conveyor path and filling the preheated mold with an excessive charge of plastisol to form a gel layer thereon while on the first conveyor path and thereafter dumping plastisol from the preheated mold for return to a supply source of plastisol; and simultaneously curing a gel layer on another of the arm assemblies by directing the mold through the second conveyor path as the preheated mold on the other end of the arm assembly is being filled and dumped whereby the movement of an arm assembly produces simultane

Abstract: Apparatus for manufacturing a multitude of thin walled hollow plastic shells for parts such as automobile door panels, controls and instrument panels from dry thermoplastic powders includes a mold heating chamber with a tube sheet heating assembly operative to provide a hot air flow pattern with a profile which matches the outer profile of one of a plurality of molds that are selectively placed in the mold heating chamber thereby to uniformly heat a casting surface of the mold by an energy efficient process.

Abstract: A highly loaded, uniform ceramic composite can be made by first preparing a highly loaded suspension. Due to the particle-particle interactions of a highly concentrated system, virtually any dopant can be added, including other suspensions, fibers, and whiskers. The process is particularly useful for making composites of materials which coagulate when mixed at low concentration.

Abstract: Apparatus for manufacturing plastic shells having decorative features thereon includes a combination mask and container unit that is joined to a known heated mold to deposit a first semi-cured deposit on the mold from supplies of material in the combination mask and container; the mask is configured to have a plurality of wire reinforced foot portions with seal edges configured to be aligned with the sharp edges of recesses in the mold surface defining the decorative feature; when the combination unit is inverted it casts material only on the recesses to form a semi-fused deposit.

Abstract: A method for manufacturing decorative features in situ in a base layer cast plastic material includes the steps of providing a mold tool having a surface thereon which is recessed in the form of a desired decorative feature and includes a sharp break line between the recess and the surrounding mold surface; depositing a covering of thermoplastic material in the recess surface and heating the tool to melt the thermoplastic material on the recess surface to form segments of plastic corresponding to the desired decorative feature; thereafter cooling the covering and stripping it from the mold by separating it at the sharp break line interface between the deposited material on the recessed surface and a thin film membrane formed on the remainder of the mold surface so as to retain segments of material deposited in the recesses of the mold tool; reheating the mold tool recess to partially remelt the retained segments and thereafter depositing a base layer of thermoplastic material across the surface of the mold an

Abstract: A method wherein an article is molded of liquid plastisol in a mold having mold heaters disposed adjacent the backside of a mold surface for controlling the temperature over respective first and second areas of the mold surface. First and second heating and cooling circuits are associated with each mold. To obtain liquid plastisol coating, the mold is filled by apparatus including a removable insert that reduces the quantity of plastisol that is used in the process to reduce the cycle time required for part molding. In one process, plastisol is pumped into and is removed from the mold with the mold insert in place. In another process the mold insert is removed from the mold and an intake tube remains in the mold to pump out excess material.

Abstract: A method for heating a plurality of molds for casting heat fusable thermoplastic material each of the molds having casting surfaces and each of the molds having outer mold profiles which differ and wherein the molds are moveable into a mold chamber including the steps of providing a hot air distributor with different tube length profiles thereon; advancing a selected mold into the heating chamber and indexing the distributor to selectively match the outer profile of a selected mold with a selected tube length profile and directing hot air through the selected tube length profile for uniformly raising the temperature of the selected mold and casting heat fusable thermoplastic material in the heated mold to cause the heat fusable thermoplastic to adhere to the casting surface.

Abstract: Suspensions of ceramic or metallic colloidal particles having a high volume fraction (greater than about 55 vol. %) solid particles are provided in a pourable form. The pourable suspension includes at least about 55 vol. % ceramic or metallic colloidal particles, an aqueous vehicle, and an acrylic acid-based polymeric polyelectrolytic dispersant. Such suspensions can be prepared by mixing the colloidal particles in a staged order of addition and under a high shear rate with the other components. The suspensions are suitable for making ceramic or metallic articles, and can exhibit a low viscosity.

Abstract: A slush mold for molding film moldings such as surface coverings of interior finishing parts of automotive vehicles. The slush mold comprises a mold body having a molding surface of a predetermined shape formed in the inner surface thereof, a skirt capable of being detachably joined to the mold body so as to cover the marginal portion of the inner surface of the mold body other than the molding surface so that a resin film molding is formed only over the molding surface, and guide members for guiding the skirt so that the skirt is joined correctly to the mold body. Thus, the molding material is distributed only over the molding surface, and thereby the yield rate of film moldings is improved and the work in the subsequent process is facilitated.

Abstract: An apparatus for the production of a synthetic resin skin uses a mold for forming at least two separate skin sections which are then joined prior or after a final heat treatment. The synthetic resin skin sections are produced in at least two separate mold members, and the skin sections are then caused to contact each other along determined faces or margins which are joined under light pressure. Any so-called selvage is easily removed after the joining which intimately bonds the skin sections to each other due to the curing of the synthetic resin.

Abstract: Apparatus and a process for manufacturing thin walled hollow plastic shells for parts such as automobile door panels, controls and instrument panels from dry thermoplastic powders includes a plurality of powder boxes and an open-ended heated mold. Each charge box is carried by an indexable carousel which has a drive motor controlled by a programmable controller to position the carousel to off-load a given color to a powder casting mold carrier which is associated with means for sequentially and continuously (1) preheating a mold; (2) dumping powder from an off-loaded color box into a heated mold; (3) curing the cast powder in the mold; (4) cooling the mold; and (5) stripping the part from the mold.

Abstract: A process is disclosed for forming at least one thin substantially uniform fluid coating comprising polymeric film forming material on a cylindrical mandrel, solidifying the fluid coating to form a uniform solid coating and separating the uniform solid coating from the mandrel. The process may comprise forming at least one thin substantially uniform fluid coating comprising polymeric film forming material around a cylindrical mandrel, the mandrel having a larger mass or lower thermal conductivity than the polymeric film forming material and a critical surface tension greater than the surface tension of the fluid coating, solidifying the fluid coating to form at least one thin substantially uniform solid coating comprising the polymeric film forming material around the cylindrical mandrel, heating both the uniform solid coating and the mandrel to a temperature at least above the apparent T.sub.

Abstract: The plastic molded article is produced by heating a mold by contact with a preheated salt bath. The salt bath is readily maintained at a uniform temperature and is self-insulating for energy efficiency. A noncontact infrared sensor monitors the mold cavity temperature while in the salt bath, and the mold is removed from the bath when the proper mold temperature is reached. A charge of plastic powder is introduced into the mold by clamping the mold to a powder slush box with the mold cavity confronting the opening of the box. The mold and box are then simultaneously rotated to pour the plastic charge into the mold. The plastic charge forms a skin on the cavity surface and additional plastic material may be built up to provide additional thickness. The mold and box are then separated; the mold is then postcured and cooled, whereupon the finished article may be removed from the mold.

Abstract: A process of producing a multiple-layer filter medium comprising a porous support and a filtering layer formed on one of opposite surfaces of the porous support.

Abstract: Apparatus for reducing the waste neck area in a mold of vinyl cast articles such as automotive arm rests, head rests and parts of similar construction includes a powder box of gellable material having a supply spout with its exposed outer surface area covered by a liner of heat insulating material; a waste inlet neck on a heated, machined nickel mold is sealed by the liner when the powder box is joined to the mold. The powder box spout is at room temperature and shields the inlet neck to prevent gel build-up on the inlet neck to effect considerable cost by both a reduction in waste deposits of gel and a reduction in labor required to trim a waste area on the mold. To obtain the coating, the mold is coated with powdered vinyl (hereinafter gellable material) by casting from the powder box to the mold and the excess material is removed from the mold by dumping it from the mold into the powder box.

Abstract: In a slush molding method of making a blood pump for an artificial heart, a heat insulating material is applied to at least a portion of the outer surface of a mold in which the blood chamber formed so that at least a part of the blood chamber is thinned in a tapered form.

Abstract: Apparatus for reducing the waste area in a mold for an article molded from a heat-fusing material by a powdered vinyl process, has a mold box disposed adjacent the backside of a mold surface for controlling the temperature over respective first and second areas of the mold surface. The waste area elimination is accomplished by isolating and insulating the section of the mold defining the waste area. A kerf is cut into the mold around the waste area to isolate the area. The kerf is filled with castable silicone to insulate the waste area from the heated segments of the mold. To obtain the coating, the mold is filled with powdered vinyl and the excess material is removed from the mold by dumping the plastisol from the mold into a return tank.

Abstract: A blood pump to be utilized as an artificial heart, comprises a housing provided with a port for introducing and discharging fluid, a cover portion for closing the housing tightly, a sac portion defining a blood chamber with the relatively flat or oval shape arranged in the housing, an inlet and outlet conduit portions for the blood provided with a check valve respectively and integrally formed on the cover so as to communicate with the blood chamber, characterized in that, when the blood chamber is compressed, the initial contact point from the opposite inner surfaces of the sac is regulated to locate in the area defined by a circle, the center of which is on the central axis of the wider side of the sac and in the height range between 0.2 L and 0.45 L from the bottom of the sac and the radius of which is 0.15 D, where L is the whole height of the sac, D is the maximum width of the sac and the wider side is defined by the side projected to the vertical plane including the maximum width D of the sac.

Abstract: Apparatus and a process for manufacturing thin walled hollow parts such as automobile crash pads from dry thermoplastic powder includes a louver type valve system in the open end of a powder charge box and means for joining the charge box end-to-end with an open-ended heated mold for rotation so that the charge box will be inverted above the mold at the end of an upward swing movement during which the valve is closed to prevent flow of powder to the mold. Once the charge box is fully inverted the valve is opened to evenly distribute the powder into the mold by gravity flow to prevent excessive build-up of wall thickness on the mold surfaces.

Abstract: A hollow shell-type hearing aid is prepared from an impression of the ear. A mold is formed from the impression. An opening is cut in the mold and the mold is filled through the opening with hardenable material. The hardenable material is allowed to cure until a hard shell of the material forms on the surface of the mold. The remaining hardenable material is poured out of the mold through the opening and the shell is then removed.

Abstract: A method wherein an article is molded of a heat-fusing material or plastisol, either liquid or dry, in a mold having an array of gas impingement jets disposed adjacent the backside of a mold surface for controlling the temperature over respective first and second areas of the mold surface. There is included first and second gas heating and cooling circuits each including a blower and dampers for supplying gas at the gas impingement jets associated with the mold. All of the gas impingement jets are supplied with heated gas to preheat the mold surface to a non-gelling temperature and a liquid plastisol coating is applied to the mold surface. To obtain the coating, the mold is filled and the excess plastisol is removed from the mold by dumping the plastisol from the mold into a dump tank.

Abstract: A molding machine has a valve assembly that includes means for selectively heating or cooling a mold by controlling flow of gas through an array of gas impingement jets disposed adjacent the backside of a mold surface to regulate the temperature over respective first and second areas of the mold surface. Gas heating and cooling circuits include two drive cylinder regulated plate valves for supplying gas at the gas impingement jet nozzles associated with the mold.

Abstract: A thin-walled work piece of plastics material is cast in a mold by pouring or flowing the plastics material in the form of a plastisol or a flowable powder into a preheated casting mold which is locked to a casting container in a sealed manner to form a closed casting cavity. The mold and the container are then lifted or rotated through at least 180.degree.. A reduced pressure is maintained in the cavity at least prior and during the tilting. After a predetermined time the reduced pressure is removed and the mold and container are tilted back into the starting position. The mold and container are then separated again and the mold is then heated for completion of the jelling or curing whereupon the mold is cooled for removing the work piece from the mold.

Abstract: The present invention relates to a method of manufacturing a medium for microfiltration, for ultrafiltration, or for reverse osmosis, wherein hydrolysis is performed on an alkoxide, an organo-metallic compound, or a metal salt of an organic or an inorganic acid, optionally dissolved in an anhydrous organic solvent, in order to obtain a sol of particles of the oxide or of the hydroxide of the corresponding chemical element, a thickening agent is added to the sol, and the resulting sol is slip cast onto a support layer having pores which are larger than pores desired for the filter medium, the thin layer deposited on the support medium is then dried, and then heat treated to eliminate the thickening agent and to sinter the particles of the deposited thin layer. The thickening agent is added to the sol in conjunction with a strong acid whose anion does not form a complex with ions of the oxide or hydroxide metal, and the slip casting is performed by mere putting into contact without filtering.

Abstract: An integrally molded plastic baseball glove utilizable in the game of baseball as a catching device for protecting the hand. The final molded article has the aesthetic appearance of a leather baseball glove. The method of making includes first molding a hollow plastic shell which forms exterior convex front and back surfaces of the baseball glove, the shell front and back surface having exterior, shaped-segments including patterned depressions and protuberances which form outlines delineating the fingers and thumb areas of the glove, a pair of webs between the thumb and index finger areas, an additional surface including cut out lines and lacing to make it look like a leather glove. The shell may be molded utilizing slush, rotation or blow-injection techniques. The mold face itself that forms the front glove shell exterior surface is not an exact replica of the final glove form but is distorted in surface configuration such that the front exterior surface when molded is convex overall.