Abstract: The present invention provides for a method and articles produced from this method for eutectically bonding together single crystal elements, such as sapphire, to form a strong bond therebetween which can withstand high temperatures and chemical attack. The eutectic bonding mixture of the present invention can include a Group IIIA compound, such as yttria.

Abstract: In a mold press forming process for integrally molding a resin core member and a surface skin member, prior to the step of forming the resin core member, a surface skin member is retained between an upper die half and a lower die half by a surface skin retaining frame which consists of a fixed segment and a moveable segment. The moveable segment is moved vertically relatively to the fixed segment to better adapt the surface skin member to a three-dimensional parting line between the upper and lower half dies. When mounting the surface skin member onto the surface skin retaining frame presents a planar mounting surface, the mounting work is facilitated, and automated mounting devices can be used without any problem.

Abstract: A decorative, multi-layered article of manufacture is described having a surface with portions of the underlying layers exposed. Multiple layers of curable thermosetting resin are cast into a mold having relief portions therein, wherein each layer has a different color. The resins are cured to form a first laminate with a substantially planar out-of-mold surface and an opposing in-mold surface having relief portions therein. Multiple layers of thermosetting resin are then cast onto the first laminate in-mold surface to follow the relief portions. Each layer has a color different from the other layers. The plurality of resins are then cured to form a second laminate, and such that the first and second laminates form an integral article having a face surface with relief portions therein and an opposing substantially planar back surface. The face surface of the article is then subjected to conditions sufficient to expose portions of the layers of the first and second laminates.

Abstract: There is provided a method of fabricating a laminated composite material and laminated composite materials fabricated thereby wherein the method includes the initial step of forming a pre-laminate by overlaying a first layer characterized by a first thermal expansion coefficient and a first ductility parameter with a second layer characterized by a second thermal expansion coefficient and a second ductility parameter. The pre-laminate is heated to a temperature at which the first ductility parameter becomes substantially equivalent in value to the second ductility parameter. The first and second layers of the heated prelaminate are then pressed together, preferably by use of a rolling mill technique, with sufficient compression force to cause the layers to adhere one to the other, thus forming a core laminate. Preferably, the core laminate is divided, either by cutting or folding, into a plurality of divided laminate members.

Abstract: A method and apparatus for manufacturing hollow plastic articles having a wall which at least partly consists of at least one core layer and two outer layers covering the core layer on both sides, in particular suitable for manufacturing preforms for bottles, wherein use is made of an injection-molding machine with a mold comprising at least one mold cavity, and an injection nozzle which, via an injection channel in the mold, connects to the mold cavity and has a central material feed channel, a needle of a controllable needle valve, which needle is active in the central material feed channel and can close or release the part of the central material feed channel located adjacent the injection channel, and at least one further material feed channel, opening into the central material feed channel, wherein first a plastic material of a first type for forming the outer layers is fed to the mold cavity and then at least one plastic material of a second type for forming at least one core layer.

Abstract: A constructed wall structure and method of fabrication that replicates a wall formed by nature. The structure has a plurality of discrete layers, with each layer constructed of concrete and a decorative additive. Every layer has an interface with an adjacent layer to thereby form a plurality of interfaces wherein at least one, and preferably most or all, of the interfaces are non-level. Non-limiting examples of decorative additives are rocks, sea shells, colorants, and mixtures thereof. Methodology for fabricating the wall structure includes pouring a first concrete mixture into a substantially vertical form and permitting a top surface to assume a non-level configuration. Preferably, a joint forming material is placed on the top surface of this first concrete mixture to thereby form a first layer of the wall. In like manner, a second concrete mixture is poured on top of the first layer and a joint forming material is included.

Abstract: A process for making a marble casting material using a solidified polymer blend having superior depth characteristics. The process involves the partial intermingling of two or more partially incompatible marble casting resins that are not intended to be normally used in combination. Due to the partial incompatibility, when the partially intermingled marble casting resins solidify, a marble effect is created.

Abstract: A method of controlling warp of electronic assemblies includes mounting a first component to one side of a substrate, the first component having a different coefficient of thermal expansion (CTE) than the substrate and thereby tending to generate bending moments that distort the shape of the first component, and mounting a second component to an opposite side of the substrate and opposite the first component. The second component has a CTE that approximately matches that of the first component, thereby tending to generate bending moments that offset the distorting bending moments.

Abstract: An improved method of manufacturing a multilayer molding having a core and a surface layer by means of a double nozzle structure can eliminate a damaging phenomenon of producing a mixture of a resin material for forming the core remaining in and out of the aperture of the inner nozzle of the double nozzle structure and a resin material for forming the surface layer in the initial stages of molding operation by effectively driving back the remaining resin into the inner nozzle. A double nozzle structure that can suitably be used with such a method includes a shut-off pin arranged in the inner nozzle disposed at the center of the outer nozzle. The resin material for forming the core is driven out simultaneously with the resin material for forming the surface layer coming from the outer nozzle. The operation of resin injection from the inner nozzle is terminated at an arbitrarily selected moment during the operation of injecting the resin material for the surface layer of the outer nozzle.

Abstract: A method is provided for forming a composite material and article using nanometer-size vapor grown carbon fibers. The preferred carbon fibers are characterized by diameters of substantially less than about one micrometer, and more typically less than about 0.2 micrometers, and are of the type formed by a continuous gas phase reaction. The polymeric matrix of the composite material is formed from a thermoplastic resin having a surface tension which is sufficiently low, so as to promote wetting of the surfaces of the nanometer-size carbon fibers. The thermoplastic resin is mixed with the carbon fibers and a solvent so as to granularize the mixture and thereby facilitate subsequent handling and mixing of the carbon fibers. Final mixing occurs at temperatures near the melting point of the thermoplastic resin and for a duration which is sufficient to ensure that the carbon fibers are adequately wetted by the thermoplastic resin, so as to provide adhesion between the fibers and the thermoplastic.

Abstract: Microlaminated composite articles are made by combining one or more sheets of flexible sintered crystalline ceramic foil with one or multiple inorganic substrate layers, e.g., of metal foil, to form a stack which is then heated below the melting temperatures of the foil and substrate layers, and under slight or moderate pressure, to provide a well-bonded composite article which is essentially free of interlaminar cementing or sealing materials.

Abstract: A method and apparatus for producing light-weight construction panels having a cementitious core layer surfaced with a layer of reinforcing fabric bonded to the two faces of the core includes the use of slurry applicator having a supporting member and a doctor in addition to a moving carrier for the slurry coated fabric. The edges of the panel also are covered with the fabric and may be open mesh edges. Cementitious slurry, for example, portland cement slurry, is applied to the fabric by means of a supporting member over which the fabric is drawn and a doctor means adjustably mounted above the supporting member. The supporting member is of a non-base-reactive material such as polypropylene or stainless steel; the use of such a supporting member permits better application of the slurry to the fabric before placement of the slurry coated fabric on the moving carrier.

Abstract: Simulated granite articles manufactured by coating a mold with a gel coat and then a spray composition including a gel coat material and crushed natural granite, crushed synthetic granite and mixtures thereof. Backing material fills the remainder of the mold. Gel coat and crushed synthetic granite may be sprayed directly on the mold, with a modified spray gun being used to efficiently and uniformly spray the granite composition.

Abstract: In the course of producing a multicolored slush skin in accordance with the powder-slush method, individual one-piece slush skins are produced in successive process steps, which extend over the entire mold, which is divided into individual color zones by means of separation fins. After the first slush skin with the first color has been produced, the area assigned to another color is cut off and this part taken out of the mold, the other part of the slush skin remaining in the mold. Subsequently a complete second slush skin is formed in the previously emptied partial area as well as in the area of the remaining first slush skin, etc. A multicolored slush skin, looking from the grain side, then is the result after it is finally taken out of the mold, which is distinguished by an exact and visually tidy separating seam between the individual color areas.

Abstract: A building element for masonry walls, particularly load-carrying walls in the foundation walls of dwellings and industrial premises and in outer walls, such as in outbuilding, the element comprises a core of insulating materials, surrounded by side members that are respectively the inner and outer side of the finished wall. Massive end members are cast in connection with the side members. Side members are made completely with concrete or of other strong materials which can easily withstand vertical and lateral loads. The end members are made of lightweight concrete or similar materials. The end members are located to connect the inner and outer walls and at the same time provide good insulation characteristics.

Abstract: A method for moulding a two-colored material includes moulding a gasket such that it has a profile which is approximately the same as a profile of one of a plurality of possible corresponding regions of the inner surface of a mould. In addition, a rigid material is embedded in the gasket and the gasket is fixed to a separation wall. The gasket and the separation wall are then inserted into the mould with the gasket being aligned along the one of the plurality of possible corresponding regions of the inner surface of the mould, such that a seal between the inner surface of the mould and the separation wall is formed and first and second half-spaces are defined within the mould. The gasket is compressed against the inner surface of the mould to improve the sealing therewith and slush moulding of a layer of a first colored material within the first half-space is performed. The layer of the first colored material is consolidated and the gasket and the separation wall are removed from the mould.

Abstract: A process for producing a concrete post having a sleeve that functions as a pouring form during pouring of the posts, a protective shield during shipping and storage thereof, and a strengthening component upon installation. The post is produced in a process whereby multiple, replacable sleeves are provided in a rack which are simultaneously filled from a hopper. The sleeve cavities are substantially free of rebar to facilitate pouring and reduce cost, the sleeve replacing the rebar as the strengthening component.

Abstract: The method includes mixing (100) degradable consumable cores (11) with a liquid coating composition (20) including an aqueous solvent (21), a hydrosoluble resin (22) and an anti-agglomerant additive (23), drying (200) the coated cores so as to obtain free balls (12) with a substrate film (2), mixing (300) these balls (12) first of all with a liquid covering substance (30) including a synthetic base product (31) and optionally an auxiliary product (32), then with an anti-agglutinant adjuvant (33), drying (400) the covered balls so as to obtain free ball structures (13) with a covering layer (3), and stoving (500) these ball structures so as to harden their covering layer and degrade the cores and thereby obtain hollow spherules (10). Application in the manufacture of intermediate products for producing in particular energy absorbers.

Abstract: Lamellar-structured highly microporous silicate compositions are provided which can be used as insulative articles and insulation material. The silicate is in the form of lamellae selected from the group consisting of mica and vermiculite. The silicate lamellae form the microporous structure, by forming the pore walls with the lamellae. Processes are described which prepare these compositions by removing the water from flocculated or unflocculated aqueous dispersions of chemically delaminated silicates while the arrangement of the lamellae in the dispersion is largely preserved, resulting in the highly microporous lamellar structure.

Abstract: A method for manufacturing a panel in which a base sheet having adhesive or all or selected parts of a surface thereof. Small stones are applied to the base sheet and a water absorbing polymer is also applied. A hardening material, such as center, is spread over the stones and the polymer. The polymer absorbs the water of the cement and expands. It is thereafter washed off or allowed to evaporate.

Abstract: A method of making a shell mould, particularly for a lost wax casting operation, includes the deposition of an adhesion agent on the pattern before the deposition of layers of ceramic material to build up the mould. The adhesion agent used is preferably a 3% solution of aminosilane in a solvent consisting of ethanol and ethyl acetate in amounts from 25% to 75% of the solvent. The method avoids the phenomenon of detachment at the pattern/ceramic interface.

Abstract: A thermofusible autoadhesive shape having nonadherent exterior surfaces consisting essentially of a thermofusible autoadhesive interior and an adherent exterior sheath of a compatible nonautoadhesive thermofusible material covering the entire outer surface of said thermofusible autoadhesive interior and the process of making such shape.

Abstract: A method for producing concrete paving stones includes slidably mounting paving stone molds in a vertical row in a rack; sliding one mold to a different depth in the rack; filling the mold with concrete; sliding the mold to its original position; and filling the other molds in a similar manner.

Abstract: A method is disclosed for the production of a multi-ply sheet product in which separate non-woven fibrous webs are combined into a multi-ply sheet before embossment, embossed as a multi-ply sheet, embossed webs separated from one another and longitudinally displaced relative to one another, and then recombined into an embossed multi-ply sheet with the embossments out of register with one another. Prior to recombining the webs, the embossments on one of said web is smoothed out increasing the absorbency and softness if the web.

Abstract: A method for molding a thin walled plastic shell utilizes the following apparatus. An apparatus (40) for molding a thin walled plastic shell includes a mold box (42) having an inner mold surface (48). A powder box (52) includes an internal chamber and first divider wall (54) for separating the internal chamber into at least two sections (56,58). A carrier framework (60) is removably mounted on the mold box (42) and includes a peripheral seal for perfecting a seal between the mold box (42) and the powder box (52) when the same are connected thereto. A second divider wall (64) is connectable to the first divider wall (54) separating the inner mold surface into two chambers continuous with the two sections of the powder box (52). The carrier framework (60) further includes a mold surface seal (66) for perfecting a seal between the second divider wall (64) and mold surface (48).

Abstract: The components forming the layers of a composite pipe are successively introduced into a rotary drum (1). Initially, a plastic reinforcing lyaer (8), including a fiber reinforcement, is introduced into the drum, the ends of the drum (1) being bounded by rings. A concrete core layer (16) is then introduced and the length of the core layer (16) is shortened relative to that of the drum (1) by shaping rings fixed to the drum ends. The shaping rings are then replaced by other shaping rings (20, 21) so that, on either side of the core layer (16), two annular spaces (22, 23) are formed which are filled by a socket material (24, 25) of the same composite as the reinforcing layer (8). Thus, at one pipe end a socket end (28) is formed and at the other pipe end a spigot end (30) is formed, each such end being located within the composite pipe wall thickness. After introducing a second reinforcing layer (26), the production of the composite pipe is completed.

Abstract: A method of constructing a wall by casting concrete within a horizontal frame which surrounds "U" shaped stud forms, which will determine vertical studs, and support members, which will determine top and bottom horizontal members. Before filling the frame with concrete the spaces between the stud forms and the support members are filled with insulating panels which are supported on the edges of the stud molds. Also before pouring the concrete, reinforcing rods may be placed in the stud molds and support members, and the reinforcing rods connected together to form an integrated reinforcing structure.

Abstract: In order to form a heating element, a coil-shaped hollow path, cut into a plate (10), is filled with an exothermally reacting pulverulent mixture and is compressed by means of a correspondingly shaped pusher (13), a platen being then applied to the upper face of the plate (10). Thereafter, the coil (2) comprised of compressed reactive mixture is lifted above the plate (10) and covered with a refractory powder to which a binder has been added and the assembly is then compressed by means of a piston (36; FIG. 6). The assembly is then placed into a metal container (5) intended to diffuse the heat for heating for example foodstuffs, after the reactive mixture has been ignited through the opening (22).

Abstract: Iron pipe and other hollow articles are lined with a cementitious mortar containing a quantity of polymer particles and the pipe is rotated about its axis so as to stratify the mortar and develop a polymer rich inner surface that is subsequently cured, dried and heated to the polymer fusion temperature and then coated with a continuous layer of pure polymer.

Abstract: A process of applying a coating composition to an underwater surface to inhibit fouling by marine organisms which includes(A) a curable polyorganosiloxane,(B) a curing agent capable of curing the polyorganosiloxane (A) to a silicone elastomer,(C) a polyisocyanate, and(D) either(D.1) a compound having more than one active hydrogen group capable of reacting with the polyisocyanate (C) to form a polyurethane, polyurea or poly(urethane-urea) or(D.2) a compound hydrolysable to (D.1).

Abstract: A speaker cone plate is provided with an inorganic surfacial hard layer formed at least on a face of a metal substrate and is subjected to a reinforcing treatment by hot isostatic pressing, wherein the surfacial hard layer may be composed of a carbide, an oxide, a borie or a phosphide or may be formed by plasma thermal spraying of an inorganic substance containing silicon nitride whiskers or silicon carbide whiskers.

Abstract: A method for making floors for filters, particularly for filters including a granular filtrating material, wherein the method includes forming two stages. The first stage is made by casting in concrete or the equivalent, at least one carrier self-supporting element or pre-slab, formed with openings in which are housed elements, such as nozzles, for the introduction of fluids used for washing the filter. Then the second stage is formed, during which, once the carrier self-supporting elements have been put in position on the supports of the filter, concrete is cast in a single operation on this element or elements, in a quantity sufficient for reaching the required total thickness of the floor and thereby providing a slab which will receive the filter granular material.

Abstract: A process for manufacturing a multilayer building panel in which one layer s a main layer comprising a binder and a reinforcing additive, and another layer contains a binder and a reinforcement such as a mat includes depositing the various layers such that one layer is deposited with an excess of water for hardening, and another with a deficiency, so that the water is caused to migrate between layers and creates a transition layer providing a gradual and continuous transition in composition between the layers.

Abstract: A method for making panels comprises the steps of forming a mixture of thermoplastic resin and organic filler and the plastication of this mixture performed simultaneously with its formation. During the transfer of the organic filler to the subsequent mixing and plastication step, the same is desiccated and mixed. Moreover, during said mixing and plastication step the plasticated mixture is transferred to a subsequent extrusion step. The method is carried out in an apparatus including a single device for the continuous production of a sheet of extruded material.

Abstract: A method of making a concrete block having decorative stones embedded in a surface thereof includes the steps of placing on a face plate a layer of stones which includes a plurality of spaced decorative surface stones and includes filler stones substantially smaller than the surface stones and disposed in the spaces between the surface stones, applying a cement mortar on the surface stones and filler stones, introducing concrete into a separate mold, inverting the face plate and placing it on top of the concrete in the mold, consolidating the concrete and assembling the concrete and the sruface stones by applying pressure and vibration, removing the mold and the face plate, and curing the resulting block without the mold.

Abstract: A method of molding oriented structural yarn/polymer matrix composite structural articles in which a preform of oriented yarn layers saturated with a resin is placed in a shape-defining mold, which is put in an enclosure, and subjected to heat and pressure to cure the resin, after which a cooling medium may be introduced. To enable the use of lightweight multi-part molds, and a mixture of pressure is distributed evenly, an internal liner is collapsed about the mold prior to curing. The process is extremely productive, and allows for accuracy and reproducibility through the use of real time temperature monitoring and closed loop feedback control.

Abstract: A lens barrel member in which an equally divided helicoid portion is provided on the inner periphery or the outer periphery of a cylinder member forming a lens barrel, and an engaging portion engaged with another lens barrel component is provided at the end of the outer periphery of the cylinder member coaxially with the helicoid portion, the cylinder member being of a sandwich-molded structure comprising a core layer and a skin layer. Also disclosed is a method of molding such lens barrel member.

Abstract: A method for molding articles such as pallets from flake-like wood particles mixed with binder, the pallets housing a deck and integral molding legs. A loosely fitted mat of wood flakes is formed by depositing a first plurality of layers of wood flakes onto a supporting surface with a flake aligners provided for causing alignment of those flakes which will form legs of the pallet. A second plurality of layers are formed with a flake aligner provided for causing alignment of flakes which will form the legs of the pallet and in a direction transverse to the direction of alignment of the flakes of the first layers.

Abstract: This invention encompasses a process for making containers from multiple stacked billets which comprises the steps of preparing thermoplastic sheet, cutting or punching billets from the sheet, stacking two or more of the billets together, heating the stacked billets or the mating surfaces of the billets to or above the fusion temperature of the mating surfaces, where the billets adhere to each other, and thermoforming the stacked billets into containers.

Abstract: A method of manufacturing a building block which imitates a pile of dry stones. According to the method, the stones (10) are placed side-by-side on the bottom of a mold whose inside shape corresponds to the desired block shape, said bottom being constituted by a grating. Cement is then cast inside the mold. The cement (11) is compressed in order to force it to spread out uniformly inside the mold and to creep between the stones (10). While the cement is kept under pressure, water is projected through the bottom grating against the outside face of the block (1), so as to remove any cement which may be found thereon. Pressure is then removed from the cement and it is allowed to set. Finally the block (1) is extracted from the mold.

Abstract: A concrete structural member of improved stability is produced by preparing a concrete composite layer having a concrete layer on one side and an aggregate layer on the other side thereof, impregnating the composite layer with a monomer, thermally or catalytically polymerizing the monomer impregnated in the composite layer, and thereafter placing fresh concrete on the aggregate layer side of the polymer-impregnated composite layer.

Abstract: An assembly line method of construction is applied to the making of the thin fiber reinforced shell that forms the external surface of the Fibrestone wall. An elongated endless movable belt has the desired recurring pattern to be applied as the external surface of the fiber reinforced shell. Spray guns movable transversely of the elongated belt are provided to spray concrete and chopped up reinforcing fibers on the belt to form a continuous Fibrestone panel strip as the belt moves past the spray guns. A plurality of elongated flex-ties mounted on suitable supports and each having one of their ends adapted to be secured to the upper surface of the fiber reinforced shell are dropped onto the spray formed shell while it is in the plastic or uncured state. To insure that the flex-ties are securely bonded additional concrete and chopped up fibers are sprayed on the flex-tie supports, and the area between the rows of flex-ties are rolled to provide a relatively smooth surface between the rows of flex-ties.

Abstract: In a molding machine wherein in molding a molded article, the molded article is molded into a so-called sandwich shape in which the central portion of the molded article is molded with core layer resin and the outer surface of the core layer is wrapped with skin layer resin, a valve for changing over and injecting the resins from a first injection cylinder for injecting the core layer resin and a second injection cylinder for injecting the skin layer resin is substantially cylindrical, a cut-away portion for changing over and distributing the resins is formed in the central portion of the valve, and sandwich molding is accomplished with the opening-closing of the cut-away portion and each passageway being effected by rotation of the valve.

Abstract: A method of making a laminated structure for use in an electrical apparatus. A female mold is produced having an upwardly facing cavity of a shape corresponding to the laminated structure. A layer of a ferrous metal is sprayed onto the bottom surface of the mold and subsequently an electrically insulated layer is applied to the layer of metal. Alternate layers of the ferrous metal and the insulating layer are deposited in the cavity of the mold to provide a laminated structure in which the metal and insulating layers are integrally bonded together. Through use of the method of the invention, a ferrous metal with the most desirable electrical characteristics can be employed.

Abstract: A fluorine-containing polymer film is prepared by flow-casting a fluorine-containing vinyl monomer, which is liquid under polymerization conditions, in the form of a film having a thickness of up to 1 mm and polymerizing the flow-cast monomer.

Abstract: A new method of construction for concrete wall structures. Precast concrete studs with fasteners protruding from one edge are used to build the framework of the walls while oriented in a horizontal plane, rigid sheet insulation is attached to the outside of the concrete studs, and wire mesh is laid upon the sheet insulation. Concrete is then poured onto the insulation, the wire and the protuding fasteners to form a continuous waterproof outer surface. New top and bottom beams which are bonded to the concrete studs are formed at the same time as the outer concrete surface. After setting of the concrete, the wall is one integral concrete structure which may be transported to a construction site for erection.

Abstract: A glass fiber-reinforced cement non-plate article which is composed of an inside mortar layer comprising a mixture of normal Portland cement and glass fiber chopped strand, an outside mortar layer comprising a mixture of normal Portland cement and glass fiber chopped strand, and a regulated set cement mortar layer interposed between said both layers and between a pair of continuous glass fiber layers, is formed.

Abstract: A method of molding a hardened glazed surface on a building block where the block is provided with a slot in the surface to be coated includes inserting a boundary edge member through the slot after the block is placed in a mold containing the coating composition; the boundary edge member conforms closely to the shape of the slot; the molding composition is cured with the boundary edge member in place and the boundary edge member is subsequently removed by forcing the member into the slot, that is away from the surface on which the composition has been molded.

Abstract: A process for forming a baluster constructed from aggregates and a binder includes depositing on a core, preferably of metal, which is subjected to a rotary movement about its axis at a speed of not more than two revolutions per second, a first layer of concrete to obtain a cylindrical mass which is joined to the core and which is compacted by the action of a knife which strikes the surface of rotation, towards which there is driven or pushed the concrete which, once dimensionally stabilized in a presetting operation, is subjected to a second operation in which there is deposited a second layer of concrete having a finer granulometry. The knife has a shape which is the negative of that which is to be given to the piece with the mass being compacted by the action of the knife. Plural successive layers with a finer granulometry and a richer proportion may be supplied until the contemplated shape and dimensions are reached.

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.