Abstract: A method is disclosed for making a facial and/or body prosthesis or appliance by means of molding and forming techniques. The material formed into the final prosthesis is a specific material uniquely adapted for the purpose. The material is a closed-cell, cross-linked, polyethylene and is in sheet form having a thickness in the range of from 1/64 inch to 1/4 inch and a density of between 11/2 and 9 pounds per cubic foot. The disclosure also includes the prosthesis per se as well as the method of making up a human face or body with the use of the prosthesis.

Abstract: Thermoplastic film, permeable to liquids, used particularly as a covering film for absorbent material, whose openings are formed as projections on one side only of the film, and having its narrowest cross-section in a plane different from that of the smooth side of the film. The cross-section of the opening widens on passing from its narrowest point towards the free edge of the projection on film. The free edge of the projection can be irregularly lobed or wrinkled.

Abstract: A process for making a multilayered formable plastic composite laminate and a process for its manufacture which includes preparing an acrylic composition which includes the reaction product of a mixture of predominantly an acrylic monomer and a substantially lesser amount of a polymer thereof, at least one free radical reaction initiating reaction catalyst, and optionally, a chain length regulating agent or a cross-linking agent; deaerating the acrylic composition; casting the deaerated acrylic composition upon a sheet or laminate of a thermoplastic material; and curing the cast acrylic composition in several successive stages so as to substantially polymerize the acrylic monomer and to permit penetration of the acrylic composition preferably to a depth of between about 0.001-0.

Abstract: A shipping protector for interposition between a shipping container and an object being shipped is provided with an interior layer of resilient plastic foam material which is self adherent to the pulp protector. The plastic foam material is vacuum formed into the interior of the pump base member and is conformed to the interior relief of the base member for resiliently receiving an object being shipped between pads of the base member.

Abstract: Uncured elastomeric sheet material (42) is built up on the outer surface of a production article (36) constructed from composite materials. A vacuum bag system (20, 24, 26, 30, 32) is used for holding the uncured elastomer member (60) against the composite article (36) while the elastomer member (60) is being cured under heat and pressure. Such curing causes the elastomer member (60) to shrink. The elastomer member (60) is then resized by cutting it into sections (66). The sections (66) are placed back on the composite article (36) and each is positioned on such article (36) at a location best conforming to it in shape. This leaves gaps (68) between the sections (66). Additional uncured elastomer (70) is applied to fill the gaps (68) and bridge across the gaps (68), to in that manner splice the sections (66) together. A vacuum bag (20, 24, 26, 30, 32) is again applied and the bag assembly (20, 24, 26, 30, 32 ) is again cured under heat and pressure, to cure the additional elastomer material (70).

Abstract: A deep drawing molding process for the formation of shaped plastic elements in which a certain thickness of the thermoplastic sheet to be formed is heated to the plastic flow state while an embossed or decorated outer side of the sheet is maintained at a temperature below the plastic state by means of a cooling air stream. The plastic element producted has an undamaged decorated side and improved wear properties such that it may be used in high ambient temperature applications, such as automobile dashboards, without cracking. The apparatus for heating and forming the plastic element includes a clamping frame to hold the sheet, a heating element disposed above the sheet, a molding box below the frame, which box is provided with inlets and outlets for cooling air and the application of vacuum, and a moldign tool also disposed above said frame, which is forced through said frame and against said sheet when a certain thickness of the sheet has been heated to the desired plastic flow temperature.

Abstract: A method of making a synthetic resin food container having a bottom wall, a side wall extending at an obtuse angle to the bottom wall and a rim or legs extending from the undersurface of the bottom wall. A device for making the container includes a male mold including a main body, a bottom forming portion received in the main body for vertical movement relative to the main body and a pressurizing portion disposed for vertical movement relative to the bottom forming portion and a female mold for receiving a portion of the bottom forming portion. The method of making the container includes the steps of forcing a portion of the bottom forcing portion into the female mold to form the bottom of the container, raising the bottom forming portion and substantially simultaneously moving the pressurizing portion to form the rim or legs on the bottom of the container.

Abstract: An apparatus and method for forming an antenna reflector panel to a desired shape. The apparatus includes a plate having a plurality of threaded holes, wherein a threaded stud is located in each one of the plurality of threaded holes. The tops of the threaded studs define the desired antenna panel contour. Two metal sheets with a honeycomb structure between them are urged against the stud tops by enclosing the fixture and drawing a vacuum therein. After the metal sheets and honeycomb structure have been held in the desired contour for a predetermined time the vacuum is released. The sheet and honeycomb structure are now permanently deformed into the desired shape.

Abstract: A machine and method for manufacturing a disposable absorbent continence pad. The machine has a series of stations including a shell-forming station for forming a shell from thermoplastic material, a slitting station for forming slits in a facing material to be sealed to a shell in order to permit the facing material to adapt to the shape of the shell and a sealing station where the facing material and the shell are heat sealed together. The shell-forming station, slitting station and sealing station have special components to assure accurate molding of the shell and prevent wrinkles in the facing material. The manufacturing method embodies a series of processing steps as carried out at the aforesaid stations.

Abstract: An improved vacuum forming process for forming a deep drawn plastic article with a flange in an area of high forming stresses wherein a mold mounted on a base forms the shape of the article. A sheet of hot plastic material is placed over the mold and a vacuum is drawn to form the plastic sheet into the shape of the mold to form the article. The improvement is forming a character in the mold portion that forms the flange in the area of the high forming stress, said character having dimensions such that properly heated plastic sheet material will be imprinted with a predetermined clarity during the molding operation. A heated sheet of plastic material is placed over the mold and a vacuum is drawn to draw the plastic material around the mold including the mold portion that forms the flange in an area of high forming stresses. The plastic material is then solidified and removed from the mold. The flange is visually inspected to determine if the imprinted character has the predetermined clarity.

Abstract: A flexible plastic cuvette belt comprises a series of open-topped chambers defining said cuvettes interconnected by webs. The chambers are generally rectangular in cross-section with their side faces having an approximately flat profile across their widths. The belt is used in conjunction with a photometric analysis station of the clinical analyzer which has a pair of spaced parallel plates which engage the cuvette side faces and render or keep them parallel. The forming press for use in the manufacture of such a cuvette belt is also disclosed.

Abstract: A diaphragm (10) suitable for extreme temperature usage, such as encountered in critical aerospace applications, is fabricated by a unique method, and of a unique combination of materials, which include multi-layered lay-ups of diaphragm materials (20a, 22, 20b) sandwiched between layers of bleeder fabric (29, 36), which, after being formed in the desired shape on a mold (26), are vacuum sealed (38) and then cured under pressure, in a heated autoclave, to produce a bond capable of withstanding extreme temperatures.

Abstract: Apparatus for forming plastic articles by a thermoform process. A plastic sheet is supported between an upper female and lower male mold. The heater assembly is moved horizontally over the sheet which is heated and caused to conform to the lower molds shape when the upper mold is lowered thereabouts, thus forming the desired object. Vacuum means retain the formed object within the upper mold assembly during separation of the molds and deposits the formed object on the top of the heater assembly upon its repositioning over the lower mold to heat a subsequent sheet. The formed object is carried away from the molds on the top of the heater assembly upon subsequent horizontal retraction of the heater assembly from between the molds. An air jet from an orifice on the top surface of the heater assembly then propells the formed object onto a conveyor belt.

Abstract: Thermoforming machines with a heating station and a downstream mold station have carrier clamp frames for gripping the edges of sheets of plastic at a load station and indexing them successively to a heating station and a mold station. The carrier frame members to which the plastic may be releasably clamped carry their own remotely operated clamps and are themselves expandable and contractible to a condition in which, prior to molding, they control the sag in the sheet formed during heating of the sheets to differential pressure forming temperature. The plastic sheet can be molded to only a portion of a product which functions as a mold member.

Abstract: Disclosed is a process of making an oriented and heat set thermoformed hollow article of poly(ethylene terephthalate) so that the sidewalls of the articles resulting from the process have a density over 1.391 cc./gm. and an onset-of-shrinkage temperature over 105.degree. C. In the process, a sheet preheated to a temperature suitable for orientation is biaxially stretch thermoformed and then while the hollow article walls are still in contact with the mold walls, the article is raised to a higher heat setting temperature in the range of about 220-250.degree. C. thus heat setting the article, and while the article is still under restraint resisting shrinkage, quenching the sidewalls of the article to a temperature that will provide a shrinkage of less than about 5% by volume and the above onset-of-shrinkage temperature of at least about 105.degree. C.

Abstract: A rigid snap-on plastic cover for a sun-damaged vinyl-covered dashboard pad is installed in an automobile without loosening or removing the dashboard pad from a dashboard substructure. The snap-on cover is made by draping a preheated softened polycarbonate sheet over a mold positioned on a narrowed support. A partial vacuum is produced in the region covered by the draped polycarbonate material, causing it to be drawn against the mold for support and to conform thereto. A skirt portion of the polycarbonate material from the support is severed after the vacuum is released, and the forward portion of the hardened polycarbonate is lifted over the mold, forcing any breakage of the "back draft" portion of the polycarbonate to occur in forward corner locations that will not be visable when the snap-on cover is installed in the automobile. The peripheral portions of the polycarbonate material are cut cleanly away and the outer surface is spray painted.

Abstract: A process and apparatus for stacking layers of composite material on moulding equipment comprises a transfer band on which each of two opposed working sections has a surface suction device to hold on it a layer that has been placed in a precise position in register with an outline, projected onto the transfer band by means of neon tubes and a frosted glass plate in a first working station. The band transfers the layer to a second working station where the layer is isolated in a sealed enclosure by means of an inflatable joint carried by a frame facing a peripheral ridge surrounding the moulding equipment. Reduced pressure is produced in the enclosure via a reduced pressure outlet causing the transfer band to be displaced towards the moulding equipment and draping the layer over the latter.

Abstract: An artificial heart valve having thin, seamless leaflets which converge to the center of a frame from the frame's inner wall. The leaflets each have a convex outflow surface and a concave inflow surface. The leaflets meet along adjacent edges to form cusps. Sinus valsalvae sections of the valve are formed as rounded recesses defined in the valve frame's inner wall as continuous curved profiles of the respective leaflet concave surfaces. The valve is fabricated by vacuum molding techniques whereby layers of elastomer are vacuum formed to comprise the leaflet and sinus valsalvae portions. In one embodiment, the leaflets are all formed from two or more layers of elastomer which are cut to define the leaflet edges or commissures. One elastomer layer extends along the frame recess to provide continuity for each leaflet and its sinus valsalvae. The resulting structure has no rims or seams in the inflow or outflow paths.

Abstract: A method of making a body cavity insert, e.g. an ear insert, comprises deforming by pressure a pressure deformable sheet of material over an impression of a body cavity, e.g. an ear canal, and separating the impression from the sheet of material without permanently disturbing the shape into which the sheet has been deformed to leave a mould cavity in the sheet of material. A moulding material is then introduced into the mould cavity to provide, when the moulding material solidifies, the body cavity insert.Typically the pressure deformable sheet of material is a sheet of non-toxic, thermoplastics material, e.g. a polycarbonate or silicon rubber material. One example of a suitable moulding material is an acrylic plastics material.

Abstract: A method and apparatus are described for cutting the web remaining from a plastic sheet containing thermoformed articles into strips, loosely indexing and aligning a plurality of thermoformed articles in each strip with article punches, sequentially isolating the articles from each other so that they have complete freedom of movement in both across-machine and machine directions, exactly registering the articles with the article punches in a selected sequence, precisely trimming the articles from the plastic web, and ejecting them from the apparatus.

Abstract: Methods and apparatus are provided for pressure and/or plug assist and match molding configurations for in-line continuous rotary thermo-forming systems. The pressure assist, plug assist and matched mold devices are carried on continuous endless loop indexing structures which accurately index them with the mold cavities in respective rotary mold wheels to achieve high thermo-forming speeds without loss of quality in the ultimate products. The drives of the continuous endless loop indexing structures are synchronized with those of the mold wheel. The systems are continuous ones in which the webs to be thermo-formed are continuously extruded and from which the thermo-formed products are continuously cut and stacked downstream of the rotary mold wheel, with the web selvage being returned and recycled into the extrusion device.

Abstract: A method of duplicating shapes embodying resinous material and more particularly fiber reinforced resinous material is taught. The method includes the formation of a mold separation sheet conforming to the mold contours, placing the separation sheet within the mold and charging the mold with the desired resinous mixture. Upon curing of the resinous mixture and ejection of the article from the mold the separation sheet is removed and discarded.

Abstract: A process and apparatus for manufacturing a polyester container having good clarity and dimensional stability and which can be used in hot-fill food package manufacture and/or in making a container for reheating or heating the contents within. In particular, this process and apparatus is a deep stretch-forming technique for preparing biaxially oriented, heat set, sealable containers of high molecular weight polyethylene terephthalate. The process comprises deep drawing a preheated sheet of the polyester into a heated female cavity by means of a male plug. The part is heat set against the female cavity, and cooled against the male plug which is used as a constraint. The part is subsequently removed from the male plug.

Abstract: A thermoplastic cylindrical clamp is manufactured by heating a flat sheet of thermoplastic material, thermoforming the softened sheet over a mold having two parallel and semicylindrical shapes with a narrow planar space between them and a coplanar flange surrounding, trimming the thermoformed sheet so the semicylinders are open at each end, locally heating the narrow planar portion between the semicylinders to the softening point, bending the softened portion so the semicylinders form a complete cylinder and cooling the part in the cylindrical shape.

Abstract: The method comprises gripping the edges of a sheet of thermoplastic resin in a drawing frame, heating the sheet to a drawing temperature, drawing the sheet within the frame against a mold to a spheroidlike hemisphere, drawing an outstanding double-walled ridge about the transverse equator of the spheroidlike hemisphere and forming a central groove in the crest of the ridge. The spheroidlike hemisphere is divided, as by sawing or routing, along the groove at the crest of the ridge and across the undrawn material, thereby forming a pair of window well covers with the undrawn material at the frame providing a first flange of each, and the two walls of the ridge providing a second flange of the respective covers. The portion of the groove remaining with each separated ridge wall provides reinforcing curl along the edge of each second flange, while excess undrawn material may be removed to trim the first flange of each cover.

Abstract: The invention provides an apparatus for forming moulded articles such as removable insoles for shoes. A blank is placed between a rigid plate corresponding to the peripheral base contour of the finished article on one side thereof and a mould bed corresponding to the shape of the article on the other side thereof. Peripheral areas of the blank are exposed by the plate and a flexible diaphragm is applied over the plate under pressure or with the aid of a vacuum after heating the blank to the softening point, to define said peripheral base contour, and to conform the other side and the exposed areas of the blank to the shape of the mould bed. In the case of shoe insoles, a range of sizes can be made with the same mould bed, using only different sizes of plate.

Abstract: A web of thermoplastic foam material is carried through an oven by an intermittently traveling conveyor engaging or gripping opposite sides of the web. The heated web is successively advanced by the conveyor between cooled heat-absorbing forming molds, which are moved toward each other to form the foam article and away from each other to release the article. A heat trimmer melts or vaporizes the leading and trailing ends of the foam material as compressed and formed by the molds, to form the marginal leading and trailing ends of the articles to the required peripheral form determined by the leading and trailing ends or edges of the molds and to separate the leading and trailing ends of the article from the web. The cooled molds, which may be made of a heat-conducting metal, such as aluminum, absorb the heat of melting as they pressurize the material along its edges and thereby determine the leading and trailing margins of the article.

Abstract: Method and apparatus for stretch-forming a hollow article from a sheet of thermoplastic material at a temperature higher than 25.degree. C. below the melting point wherein a stretching tool having at least one tip at a temperature lower than 50.degree. C. below the melting point is pressed against the sheet, and the initially stretched sheet is then further stretched and simultaneously dilated. One form of tool comprises a number of blades arranged around a plunger which are moved forward and outwardly after initially stretching the sheet forwardly. The articles so produced can be further formed by blow moulding.

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: A method of deep drawing of foam material mold parts made of flat foamed plates, by which the plate which is clamped in a frame is heated on both sides and is sucked against the upper side of a core piece which moves into the plane of the frame, the upper side corresponding to the profile of the mold. The suction takes place with an intermediate placement of a foil, the latter being adhesive material--repelling at least on its interior side. The foil is fastened to the foam material plate by means of a self-adhesive layer.

Abstract: Apparatus and method for draw molding elongated hollow articles from thermoplastic material which is desirably stretch moldable plastic sheet or film. The material is draw molded on an elongated mandrel. Draw ring means are operated cooperatively with the mandrel for drawing the thermoplastic material into an elongated hollow article. Gaseous jet stream doctoring means are operated during drawing for controlling the article wall thickness. The material may be drawn through a wiper ring through which the mandrel is moved with the thermoplastic material during draw molding in combination with subjecting the outer surface of the article being drawn to the action of the doctoring jet stream from an annular orifice. Internal fluid conditioning of the mandrel, as well as alternate negative pressure within the article during molding and stripping pressure from the mandrel into the article at conclusion of molding cycle are provided for. The draw molding is effected without clamping the thermoplastic material.

Abstract: Breast pads, cups and fronts for use in brassieres and other garments are molded from a thin, generally planar blank of an open-cell or closed-cell polymeric foam material (e.g. polyurethane). The blank is placed between mold parts and the male mold part then deforms the blank into the configuration of the female mold part while negative pressure is exerted on the female mold part, thereby causing the blank to be seated in the configuration of the female mold part. The male mold part is then withdrawn, negative pressure is discontinued and the male mold is again placed in contact with the blank and heat and positive pressure are simultaneously applied to the mold parts to cause compression of the cells of the blank and to thereby cause the cells to become permanently reformed into their compressed positions.

Abstract: An improved thermoforming process for the production of formed articles of corrugated plastic board having small radius curvatures and deep drawings, which comprises heating said corrugated plastic board at the portions to be formed into small radius curvatures or deep drawings more intensively than at the other portions, and applying pressure to said portions thereby crushing the rib structure in said portions without crushing the rib structure in said other portions.

Abstract: This invention pertains to a method for thermoforming thin-walled plastics articles from an elongated polyolefin web which is manufactured so as to have minimum orientation so that it will expand lengthwise and widthwise when passed through a heating zone prior to thermoforming, which method comprises moving the web both laterally and longitudinally in a co-ordinated manner whereby the normal inclination of the web to sag because of the longitudinal and lateral expansion of the web due to heating is effectively eliminated.

Abstract: A decorative container useful for holding a flower pot or the like, and formed by the method of arranging a sheet of thermoplastic polymer upon a form, the form having a shape generally desired for the sheet after it has been molded into the configuration of the form, with said sheet and form being positioned within a heater, with the temperature within the heater being warmed to an elevated degree, and then maintaining the form held sheet within this heated environment for that time necessary for the sheet to soften and fold under the influence of heat into its decorative container configuration, and thereafter removing the heat formed sheet from the heater and cooling it to an ambient temperature.

Abstract: In manufacturing of a mold for metal casting via the vacuum molding process, the cover for the original pattern is made of a synthetic film including, at least partly, ionomer resin component and, further preferably, the exposed surface of the cover set to the pattern is coated with a solution of an initial condensate of a thermosetting resin.High fidelity in patterning, excellent vacuum retainability, enhanced surface stability and high resistance against thermal decomposition of the ionomer cover film accompanied with considerably reduced casting defects assures high quality of the castings obtained.

Abstract: This invention is a method for forming an antenna reflector and housing f a plastic material, rather than from metal or a glass/cloth laminate. The method comprises the steps of scribing a grid structure on a plastic sheet; vacuum or gavity forming the plastic sheet and trimming it to size; coating the plastic sheet with a conductive metal such as copper; and then removing the excess copper from the antenna. Alternatively, a printing and etching technique can be used in substitution of the scribing coating steps.