Abstract: An unsupported decorative film of a polymeric composition having controlled permanent tack, the polymeric composition being a blend of 86 to 88% of a polyvinyl acetate-acrylic copolymer of high molecular weight and low residual tack and 12 to 14% of a polyvinyl acetate-maleate copolymer of low molecular weight and high residual tack. Other chemicals may be added to the blend to control color, viscosity and resistance to microorganisms. A casted film of this composition adheres to most surfaces, but may be forcefully removed and relocated. The film is used for decorative art pieces.

Abstract: Disclosed herein is a new method and new apparatus for applying fibrous reinforcements to a thermoformed plastic sheet comprising a base bearing, an upper support having a gutter, a plastic membrane, and a seal bounding the gutter so that when air is drawn from the outlet and at least partial vacuum is formed between the membrane and the surface.

Abstract: Concrete building panels include a decorative embossed pattern on an outer surface. A plurality of concrete reinforcing ribs are disposed along an inner surface of the concrete building panels. Nailing strips are anchored into tips of the respective concrete reinforcing ribs. A method for making the building panels include a step of placing anchored nailing strips into tapered rib sections of a horizontal fiberglass mold is disclosed wherein reinforcing bars and mesh and moist concrete are placed into the mold and allowed to cure until the exposed upper surface of the moist concrete is plastically deformable. The horizontal mold is passed beneath a rotating embossing roller having a cylindrical embossing pattern thereon. The plastically deformable concrete contacts the embossing pattern, producing a complementary pattern on the concrete surface. The embossed concrete is cured in the mold to produce the building panel. The concrete building panel is then separated from the mold.

Abstract: A method of making a composite structure upon a solid former having a low melting point, comprises placing the former together with the laid-up composite within a mould, raising the temperature of the mould such as to melt the former and expand it such that it consolidates the composite within the mould.

Abstract: Method and apparatus for manufacturing laminant veneers for application to the teeth of a dental patient. The method involves heat and fluid pressure induced forming of a dental laminant veneer to cause the veneer to assume the configuration of a standard mold or a model mold of a dental patient's teeth. The apparatus includes a heat chamber and means to move the dental veneers and mold and the heat chamber into interrelation to cause heat softening of the veneers. A flexible membrane is pressure induced by vacuum or positive pressure and causes the softened veneers to assume the configuration of the mold.

Abstract: The specification discloses an apparatus and method for molding glass fiber reinforced polyester resin articles. A bladder-covered male mold is in turn covered with resin and reinforcement and a female mold with a surface forming film located therein or with a smooth surface is then closed over the male mold. With the bladder held against the male mold by vacuum, air is evacuated from between the bladder and the female mold. The vacuum between the bladder and the male mold is then released whereby the bladder is forced against the resin to thereby force it against the film which is located within the female mold or against the mold surface. This insures a molded article with a bubble free surface. Where a film is used, this insures a tight air free bond between the resin and the film.

Abstract: A mold for the production of a reinforced plastic tubular body having an annular groove such as a pipe coupling, the mold having a mold body and detachably mounted on a predetermined position thereof, an annular groove former consisting of a surface layer of an elastic material and a core covered with the surface layer. The reinforced plastic tubular body is produced by forming a layer of a molding material around the aforesaid mold, curing the layer of molding material, separating the mold body from the cured layer of molding material, and then separating the annular groove former from the cured layer of molding material by removing the core and then removing the surface layer.

Abstract: A method for manufacturing a resin-reinforced carbon fiber bar product in which thermal setting resin-impregnated carbon fibers are heated to a temperature sufficient to set the resin to semi-solid state, the heated carbon fibers are passed through resilient constriction means to form a bar-like intermediate product, the bar-like intermediate product is cooled, a tape of water-containing cellophane is wound about the intermediate bar-like product in a spiral manner to compress the carbon fibers together, the intermediate bar-like product is pulled in the longitudinal direction while being heated, the thus treated intermediate bar-like product is cooled and the cellophane tape is removed from the intermediate bar-like product to thereby form a complete resin-reinforced bar product.

Abstract: A molding process for compression molding blanks from a polymerizable, thermosetting resinous composition in which pearlescent particulate materials are mixed: Upper and lower mold parts, at least one of which has mold cavities formed in it, are held in an open condition. The resinous composition is sandwiched between two sheets of a film material and is placed on the lower mold part. At least one of the layers of film material is stretchable. The mold parts are moved together until the upper mold part contacts, without applying pressure to, the top of the resinous composition. The mold parts are held at this semi-closed condition for a period of time at an elevated temperature, thereby causing the viscosity of the resinous composition to rise significantly. The mold parts are then moved to the fully closed condition at which molding pressure is applied to the resinous material, and the resinous composition is then forced into and shaped by the mold cavities in the mold parts.

Abstract: A method of producing a bonded laminate by sealing round the edges of a pair of face-to-face spaced sheets of frangible material, introducing into the envelope so formed a liquid resin composition and solidifying the liquid, the seal around the sheets being formed by gas-permeable, resin-impermeable material so that when the resin is introduced the sheets can be sealed completely and trapped air can escape through the seal. This permits very precise control of the amount of resin in the laminate and avoids difficulties involved in the removal of air bubbles.

Abstract: A thin sheet having a low rigidity is drawn while being depressed over the radiused corner of a die by elastic force or hydrostatic force to obtain a formed article whose sidewall part and flange part have no wrinkles. The force is applied through an elastic rubber provided around the punch and having an outside diameter larger than the inside diameter of the die cavity, or through an annular rigid body on which elastic pressure or fluid pressure is exerted. The hardness of the rubber is preferably approximately 70 to 85 in accordance with ASTM D 2240 Durometer A. A laminate not more than about 200 .mu.m in thickness and consisting of a thermoplastic resin film, aluminum foil and a heat-sealable resin film is drawn into a formed article or a container which is light in weight and suitable for containing foods, for instance.

Abstract: A method for manufacturing laminated skis wherein the molds in which the skis are built are vacuum wrapped with a plastic film prior to the placement of the ski components in the molds. The adhesive-coated ski components are then placed in the vacuum-wrapped molds in proper fashion. The mold-component assembly is then placed in a press when the ski is formed under pressure and heated so as to set the adhesive. The ski is then stripped off of the mold, the plastic wrap adhering to the ski and leaving behind a clean mold. The plastic wrap is then removed from the ski.

Abstract: To provide asbestos-cement and like sheets which are formed by build-up of a thin film on a rotating size roll, with an embossed patterned surface; a flexible mold layer of epoxy resin or like moldable material having counterpart embossments molded thereon, is removably wrapped about and secured to the size roll with its patterned side outward and before commencement of film build-up on the roll.

Abstract: Thin thermoplastic film is reformed to provide matching elements for surfaces of complex curvature, such as the surfaces of compound or aspheric glass lenses. The film is hot-pressed between the curved surface to be matched and a pressing piece of similar curvature, formed by casting a low-melting-point alloy against the curved surface to be matched.

Abstract: A method for the preparation of composite products wherein a foam expands in contact with a laminated sheet, one of the layers of which is metallic, the pressure generated during expansion of a foam forces the laminated sheet to adopt a desired configuration and the foam adheres to the laminated sheet. Composite products having a mirror-like appearance may be prepared by the method.

Abstract: Reinforced facings, including reinforcing webs entrained in hydraulic cement via a slurry bath, adhere to a nailable lightweight aggregate cementitious core to form a panel web. The reinforced web is formed on abutting conveyed carrier sheets, and the web is transversely cut, between the sheets, while moving or when stopped, in response to sensing of the sheets. The cut panels, on respective sheets are stacked for curing without damaging the panel edges and in a manner to minimize panel flex. Slurry bath, facing applicators, and cutter and stacking apparatus are included.

Abstract: The invention relates to a method of producing a molded plastic article simulating a base having one or more headed shanks extending therefrom by an injection molding operation using a specially shaped mold followed by deforming of the molded article by a heated platen.

Abstract: The present invention is concerned with a method for the manufacture of objects having two shaped surfaces from setting material such as cement and gypsum mixtures. In this method a discrete quantity of the setting material is applied to a mold portion having a surface corresponding to one of the shaped surfaces of the object and is permitted to set therein. The improvement of the invention comprises the application of a discrete quantity of the setting material also to a mold portion having a surface corresponding to the second shaped surface of the desired object. The two mold portions are then brought together to form a mold while the setting material contained therein is still shapable. Hereby the quantities of shapable material are pressed against each other to form the desired object. The latter is then separated from the mold portions.

Abstract: Crinkle-free tube bends can be produced by introducing a flexible core into the straight tube length to be bent, bending the tube length around movable templates at the optimum thermoforming temperature and, while bending, laying an extensible insert between the tube length and the bending template.

Abstract: An improved process for forming cast articles of plaster reinforced with fibers is disclosed wherein low consistency plaster slurries that include a fluidizing agent and fibrous reinforcing materials are co-sprayed onto a sectionalized casting bed having a flexible membrane section connecting rigid sheet forming bed portions; allowed to stand in a horizontal position through initial stiffening; and then before the slurry has set, the sectionalized casting bed is reformed so as to produce a contoured shape to the gypsum cement sheet.

Abstract: A stereo relief modelling apparatus based on photogrammetric method and apparatus comprising a flexible platen, used with standard stereo plotting instrumentation such as double-projection direct-viewing plotting instruments. The purpose of the flexible platen is to provide an absolute stereo image for photographic, modelling and other purposes. The flexible platen, which is of sufficient size to provide a meaningful mapping surface, is vertically adjustable at a multiplicity of points by mechanical, pneumatic, electro-mechanical, fully automated, or other means to provide an actual model-like three-dimensional photographic or modelling surface to enable relief distortion from aerial photographs to be effectively eliminated in planimetric photographs which are taken of the adjusted flexible platen, or models molded on the adjusted flexible platen, upon which the aerial images are projected. Modelling is facilitated by situating the platen inside a sealable vacuum box from which the air is removable.

Abstract: A device for applying exposed aggregate, which is utilized on the exterior and interior of building and home construction, as well as other structures, has been developed that consists of a rigid to flexible type backing with a resilient material such as foam or the like attached thereto forming the face of the device. It is essential to the device of the present invention that the resilient material forming the face of the device has sufficient resiliency to insure that aggregate that is placed thereon will not easily roll off the face of said device and yet in no way inhibit the adhesion of the exposed aggregate on a prepared surface when applied. In utilizing the device of the present invention and in carrying out the method of the present invention, aggregate is placed on the face of any number of devices of the present invention and such devices are used to directly apply aggregate to a surface such as a wall which has been prepared to receive exposed aggregate.

Abstract: The invention relates to a method and apparatus for making hollow, resin-impregnated fibrous fabric articles. Specifically, it relates to a method wherein a reusable mandrel is made sufficiently rigid to receive a lay-up of the article to be manufactured. The rigidized assembly is placed within a female mold, derigidized and expanded to apply pressure from within, thereby forcing the lay-up against the interior of the mold. Heat is applied to cure the resin, producing an article having a very high degree of dimensional accuracy.

Abstract: A method of making a vacuum blanket for vacuum curing elastomeric and plastic materials and more specifically, it relates to making a vacuum blanket by spray coating a polyurethane liquid reaction mixture.

Abstract: A method and apparatus are disclosed for preshaping a sheet material, more particularly a textile and/or a plastic sheet, under differential pressure in a molding die, whereby to form a sack-like structure which becomes integrally incorporated as the cover of a foamed plastic cushion, vehicle seat, protective padding element or similar article, by the introduction of a self-foaming elastomeric material into the sack while it is being held in the molding die.

Abstract: A method for forming a flat, thin polyester film into a curved film using heat, peripheral support for the film, and a single die.

Abstract: A membrane of a porous unexpanded polytetrafluoroethylene (PTFE), such as that made by the matrix technique disclosed in U.S. Pat. No. 3,497,256, issued Feb. 24, 1970, in sheet form is sandwiched between metal foil layers that are stiff enough to take a dead set crimp; the three layer composite is passed through corrugating gears; the corrugated composite is indexed between two grooved plates under moderate pressure and the composite is heated while between the plates to heat set the plastic membrane; then the metal foil layers are removed after cooling.

Abstract: In a method for forming castings made from a polymerizable hydrophobic monomeric material wherein a liquid hydrophobic polymerizable plastic monomer material is pumped into a cavity, which is defined by a pair of spaced apart smooth surfaced plates that are sealed about the outer perimeter, and polymerized therein to a solid, self-supporting casting, the improvement comprising the preliminary step of applying the relatively thin thermoplastic sheet across at least a portion of at least one of the spaced apart smooth surfaces, said thermoplastic sheet stretching when in contact with the liquid polymerizable monomer material during polymerization of said material and during cooling of said polymerized material, the sheet shrinking and distorting in random fashion so as to produce a randomly textured surface on at least the corresponding adjacent portion of the polymerized casting.

Abstract: The invention is concerned with the problem of holding in place a plurality of bricks, stones, tiles or the like while they are being assembled into a pre-formed panel for subsequent incorporation into a building or like structure. It has been discovered that the elements can be frozen into place on a water-saturated base surface without any detrimental effect on the setting characteristics of the mortar or other adhesive used to bind the elements. The invention also provides apparatus for carrying out the method.

Abstract: A horizontal brick feed conveyor continuously feeds green undried moist clay bricks along a path beneath a lower horizontal flight of an elastic hold-down belt member mounted above and moving in the same direction as the conveyor to engage the upper surface of the conveyed brick; a relatively large motor-driven irregularly spaced impression roller is adjustably mounted adjacent the upper surface of the horizontal flight of the hold-down belt to engage the horizontal flight so that a number of protrusions on the roller deflect portions of the elastic hold-down belt downwardly into the green brick immediately beneath the hold-down belt so that the bricks are distorted and misshaped to give an antique or handmade effect.

Abstract: A method and apparatus for making flat topped foamed buns (e.g. polyurethane) in a continuous foaming process. The method comprises the guiding of a continuous thin film tubular member through gathering devices adjacent the cream line at each side of a conveyor, and subsequently guiding the tubular members upward along guides at an angle and rate determined in accordance with the rate of longitudinal travel and the rate of rise of the foaming reactants so as to encourage the sides of the bun into the same height of rise as the center region of the bun. Continuous slitting of the tubular members at the appropriate elevation allows the material thereof to progress longitudinally with the cured bun.

Abstract: A process for producing a synthetic resin article having an excellent resistance to surface abrasion is described which is characterized by having a synthetic resin surface layer, firmly adhered to the base resin, the synthetic resin surface layer comprising a polymer or copolymer containing at least 40% by weight in polymerized form of at least one compound having a total of at least three acryloxy (CH.sub.2 .dbd.CH.CO.0-) and/or methacryloxy (CH.sub.2 .dbd.CH(CH.sub.3)CO.O-) groups in the molecule. The article is prepared by (1) forming the above synthetic resin layer on the inner surface of a mold and then, charging a monomer for base resin into the mold and polymerizing the monomer, or (2) directly forming the synthetic resin surface layer on the surface of a synthetic resin shaped article.

Abstract: A method and apparatus for forming large fiber-reinforced foamed plastic panels is disclosed. The panels are produced by a process comprising filling a flat mold with freshly mixed foam plastic precursors, including fibrous material for reinforcement of the panels, closing the mold until the plastic precursors have foamed and set, then opening the mold and removing the finished panel. The apparatus comprises a platen mounted for traversing under the dispensing outlet of a mixing device, whereby the platen is filled with foamed plastic precursors, and a press into which the platen travels before the mixture has begun to mold. The press is provided with a novel mechanism for closing the mold by placing a cover on top of the platen before the plastic begins to foam. The same mechanism is adapted to open the mold by lifting the platen cover. Thereafter, the platen is moved in a reverse of its entry movement, returning to its starting position for removal of the finished panel.

Abstract: Typically, injection molded expandable thermoplastics exhibit imperfect surfaces in the form of mottled areas, visible flow lines, and pin holes; these imperfections are caused by the quick chilling of the surface of the expanded thermoplastic as it contacts the mold surface. This invention is a method of injection molding expanded thermoplastics free of these defects by injecting a short-shot of the expandable thermoplastic into an elastic membrane positioned within a cooled mold cavity, containing the short-shot within the membrane until a skin forms on the thermoplastic in contact with the membrane, and then permitting expansion of the thermoplastic in the cavity to form a smooth skin or surface on a substantial portion of the article.

Abstract: Molding thermoformable textile fabric (knit, woven or otherwise), and particularly stretch fabric, into a permanent three-dimensional shape by vacuum-molding in a cavity in a vacuum mold, wherein flow of air through the fabric is blocked to enable it to be vacuum-formed by means of a layer of substantially air-impervious thermoformable sheet plastic material applied over the fabric. The plastic is heated to thermoforming temperature, the plastic and fabric are vacuum-formed in the mold, the molded plastic layer with the molded fabric thereon being removed from the mold and the molded plastic layer being utilized as a form for holding the molded fabric in its molded shape for a sufficient period of time to stabilize the fabric in its molded shape. The molded plastic layer is cooled within the mold via a flow of cooling air.

Abstract: A process for making a valve housing for a prosthetic socket. The process eliminates the need for a male and female mold by applying an elastic resilient separator material over the entire surface area of a housing mold, sealing one end of the material to enclose the surface area of the housing mold, applying a vacuum to the sealed material so that the material closely conforms to the entire surface area, applying an outer elastic resilient separator material to the housing mold over the reinforcing materials so as to trap the reinforcing materials to control thickness and shape, applying a vacuum thereto to force the outer elastic resilient separator and underlying reinforcement material to closely conform to the housing mold; and adding the resin molding material to impregnate the reinforcing materials.

Abstract: A process for artificially forming rocks is described. The process provides for forming a rubber film mold of the surface of a natural rock. The rubber film mold is then placed on a bed of flowable supporting elements which are distributed to support the underside of the cavity of the rubber film mold such that it assumes a desired contour or shape. A filling of concrete poured into the cavity of the mold upon hardening and being turned over provides an artificial rock whose surface has the characteristic markings of the natural rock but may have any desired different overall contour or shape.

Abstract: The invention relates to a method for producing a guiding device for flexible materials in which an element, representing the actual guide passage to be produced, is made with the aid of a malleable material; the element is positioned in a mould which has the general shape of the outer contour of the device to be produced; a resin is cast inside this mould and onto the element, and the malleable material constituting the inner element is then eliminated with the aid of an agent which has no action on the resin.