Abstract: The present invention discloses a process for producing molded, shaped or extruded articles comprising the steps of:a) melt reacting, in the presence of a catalyst which is substantially free of Co compounds, at least one glycol and at least one dicarboxylic acid to form a polyester having an I.V. of at least about 0.5 dL/g, wherein said at least one glycol is selected from the group consisting of glycols having up to 10 carbon atoms and mixtures thereof and said dicarboxylic is selected from the group consisting of alkyl dicarboxylic acids having 2 to 16 carbon atoms, aryl dicarboxylic acids having 8 to 16 carbon atoms and mixtures thereof;b) adding an acetaldehyde reducing additive to said polyester to form a reduced acetaldehyde polyester; andc) forming said reduced acetaldehyde polyester into articles directly from step b.Thus, the present invention provides a process for directly producing from the melt article having extremely low acetaldehyde content.

Abstract: The present invention discloses a process comprising forming a preform with planar stretch ratios greater than about 14 from a polyester having a natural stretch ratio which is substantially matched to the preform planar stretch ratio at processing conditions; and stretch blow molding said preform to produce a container. Suitable natural stretch ratios include those greater than about 13 at 210.degree. F. The desired natural stretch ratios and desirable final container properties are achieved by balancing the appropriate I.V. and copolymer modification.

Abstract: The invention seeks to position a thermoplastic container or container preform having a neck (1) with a substantially circularly cylindrical inside wall (2) in a predetermined angular position on a mandrel (11) inserted into the neck (1); the inside wall (2) of the neck (1) includes at least one approximately radial projection (8), and the outside wall (13) of the mandrel includes at least one thrust shoulder (14) facing towards the free end of the mandrel, to guide the radial projection, the shoulder (14) extending over the wall and being inclined relative to the axis of the mandrel, looking means is also provided to stop relative movement of the mandrel and of the container when the neck thereof is disposed in a predetermined angular orientation relative to the mandrel.

Abstract: A method of manufacturing a hand covering with a pad attached thereto wherein a pad is placed in a recess on a former, and a precursor material such as liquid latex is thereafter applied to the former and pad. The precursor material is then cured to form the hand covering, which is stripped from the former and everted for use with the pad bonded thereto.

Abstract: A rigid three-dimensional preform is made by moving a plurality of webs of fibrous reinforcement material superposed and coplanar to a cutter, the webs being coated with an electromagnetic energy-curable binder and pressed together. Prior to cutting a blank in a two-dimensional development of the three-dimensional preform from the webs, the webs are tacked together at spaced local zones by locally curing the binder at those zones by locally applying the appropriate electromagnetic radiation (microwave, ultraviolet, electron) so that the webs travel as one to the cutter. After cutting of the blank, the blank is loaded into a mold to replicate the three-dimensional shape of the preform and the remainder of the binder is cured in the mold by the application of the appropriate electromagnetic radiation.

Abstract: Si.sub.3 N.sub.4 -based sintered compositions containing MgO and optionally other sintering additives, which after sintering, has a flexural strength level at room temperatures of .gtoreq.800 MPa, measured by the four-point bending method, and a Weibull modulus of >15, is produced by mixing MgO, any additional sintering additives and Si.sub.3 N.sub.4 powder to form a mixture, calcining the mixture in an oxygen-free atmosphere to obtain a pre-synthesis mixture, and adding the pre-synthesis mixture to uncalcined Si.sub.3 N.sub.4 powder which is then sintered.

Abstract: An aircraft wing, a fusion bonded thermoplastic fixed leading edge structure for aircraft aerodynamic surfaces and a method of manufacture are provided. The fixed leading edge structure comprises a leading edge skin (28), one or more aerodynamic profile defining stiffening members (17, 18) spaced spanwise therewithin and a sub-spar. Each of the components are of low modulus consolidated composite material and the leading edge skin (28) is attached to the stiffening members (17, 18) and to the sub-spar by a fusion-bonding thermoplastic process.

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: UV-transparent forming tools or molds are prepared for molding resins comprising a urethane acrylate, e.g. urethane dimethacrylate oligomer, and an alpha,beta-ethylenically unsaturated monomer, e.g., styrene, cured in the presence of a peroxide initiator. The resins are tough, durable and have a wide range of other desirable properties.

Abstract: A self-reinforced polymer composite in the form of a non-laminated shaped article is prepared by (a) melt blending (I) a matrix polymer which is a melt processable flexible chain polymer or first liquid crystal polymer (LCP) and (2) a fiber forming melt processable second LCP under high strain mixing conditions inducing fiber formation, cooling and stretching the resulting blend, and (b) shaping the resulting blend by injection molding or extrusion at a temperature which is above the minimum melt processing temperature of the matrix polymer but below that of the fiber forming second LCP. By shaping at a temperature below the minimum processing temperature of the fiber-forming LCP, the fiber structure formed during cooling is preserved. The resulting shaped articles have outstanding mechanical properties, e./g., tensile strength, modulus and impact strength.

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: A plastic connector housing (50) having a plurality of contacts secured therewithin is securable to and within a protective metal shell (12) without a bead of liquid adhesive placed therebetween during assembly, by forming a shallow peripheral channel (76) in a housing flange forward surface (74) and a shallow recess (30) in an abutting rearward surface (24) of a corresponding shell flange (18), the channel and recess defining a confined seal seat (80) extending around the housing body section (70). Lengths of solid sealant preforms (90) such as of epoxy are disposed along the channel during assembly, and the shell (12) and housing (50) held together and heated, thereby melting the sealant to flow and bond to the surfaces of the channel and recess, both joining the housing (50) to the shell (12) and forming a hermetic seal (92) along the interface therebetween, recessed from outer surfaces of the connector (10).

Abstract: A method for molding articles, particularly tires, of different diameters/circumferences including a plurality of pitches defining a mold cavity, the pitches having transverse faces in generally face-to-face abutment in a closed position of the mold cavity, and at least several of the pitches being of different lengthwise sizes. The pitches in the closed position of the mold cavity defining a predetermined mold configuration which includes portions at angles to the length of the article molded in the mold cavity. The mold configuration matches lengthwise across all of the transverse faces irrespective of the location of the pitches relative to each other and irrespective of the number of the pitches. The latter arrangement permits articles, such as new or retread tires, of different lengths but of the generally same predetermined mold configuration to be molded in a single mold.

Abstract: Described are smooth, glossy finished fiber reinforced thermoplastic prepreg materials composed of reinforcement fibers impregnated with and surrounded by thermoplastic. Prior to consolidation, the material preferably consists of thermoplastic fibers and reinforcing fibers, intimately blended together. When heated, with the aid of pressure, the thermoplastic fibers melt, surround and impregnate the reinforcing fibers and provide a smooth, glossy finish to the reinforced article. Excellent surface appearance and the ability to accommodate high-speed processing characterize the prepreg materials of this invention.

Abstract: Fiber reinforced thermoplastic molded products, sheets, and the like, having a glossy surface are produced by intimately blending discrete reinforcing fibers (e.g. fiberglass) and thermoplastic fibers (e.g. polypropylene or polycarbonate) into a web. The web is heated to the melting point of the thermoplastic fibers while applying pressure, to eliminate air and press the web into a consolidated structure. Breakage of the reinforcing fibers is minimized by limiting the thickness of the web and limiting the pressure so as to produce a consolidated structure with minimal fiber breakage and a Notched Izod of at least one. Layering consolidated structures, some without reinforcing fibers, may be heated and pressed together to form a final structure having a thickness greater than the individual structures. The great majority of the fibers are provided so that the fibers of each type are within the range of about 0.5-5 inches.

Abstract: The invention relates to a vacuum mold for manufacturing cushions with back-foamed covers, wherein a section of cover material is stretched across a mold cavity, held down at the rim of the cavity, but allowed to slide into the mold cavity under the influence of a vacuum. The cover is also placed against and fitted to contourings (ridges and/or grooves) of the mold cavity, and subsequently back-foamed. The resulting flexible foam core is allowed to harden and the finished cushion is removed from the form.

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: This invention relates to a process for the production of high strength polybenzimidazole filaments and molded products made from such filaments. The filaments produced by this process contain from about 10 to about 50 percent by weight residual solvent and can be heated at a temperature of about 350.degree. C. to about 600.degree. C. to produce three-dimensional foamed articles.

Abstract: Thermosetting fluorodiepoxide polymer foams are made by mixing fluid form thermosetting fluorodiepoxide polymer components having a substantial fluorine content, placing the mixture in a pressure tight chamber, filling the chamber with a gas, at relatively low pressure, that is unreactive with the fluorodiepoxide polymer components, allowing the mixture to gel, removing the gelled fluorodiepoxide polymer from the chamber and thereafter heating the fluorodiepoxide polymer at a relatively low temperature to simultaneously cure and foam the fluorodiepoxide polymer. The resulting fluorodiepoxide polymer product is closed celled with the cells storing the gas employed for foaming.

Abstract: A method of manufacturing a plastic molding of a foamable thermoplastic raw material blank or preform which contains a foaming agent by high frequency voltage heating in a molding die assembly defining a molding cavity, wherein gas discharging openings which extend through the thickness of the blank or preform are preformed in the raw material blank or preform.

Abstract: A method is disclosed for making a part with a smooth surface, such as an exterior automotive body panel, by compression molding a charge containing a curable resin. The charge is placed on the molding surface of one of the dies so that the charge covers 40%-80% of the surface area of the molding surface. The molds are moved to a partially closed position and the mold cavity is quickly evacuated. The mold is then closed so that the dies compress the charge to cause it to fill the mold cavity and, after the resin cures, the part is removed from the mold.

Abstract: Process for the preparation of bodies of expanded cross-linked polyethylene, with closed cells, comprising the steps of:melting a polymer of ethylene selected among ethylene homopolymers, copolymers of ethylene with alpha-olefins, copolymers of ethylene with conjugated diolefins and relevant mixtures;homogenizing the polymer of ethylene in the molten state with a quantity of from 0.1 to 2.5% by weight of a cross-linking agent and with a quantity of from 2 to 25% by weight of an expanding agent, the cross-linking agent and expanding agent having a decomposition temperature higher than the melting point of the polymer of ethylene, the homogenizing step operating at temperatures of from 130.degree. to 150.degree. C., and for times of from 5 to 10 minutes;forming the homogeneous mixture in a solid parallelepiped shape by means of extrusion and subsequent cooling, or by means of moulding wherein the extrusion or moulding step is operated at temperatures within the range of from 130.degree. to 150.degree. C.

Abstract: Aromatic polymer materials, such as polyethersulphone, polysulphone or polycarbonates in granular or porous forms with a solvent such as acetone or butanone. The resultant mixture is thereafter compressed and compounded to significantly increase its density producing a pre-form substantially free of large irregular voids. The preform is then capable of being formed in a foamed structure under heat.

Abstract: A preform for use in making a video recorded disc in a body of plastic material having substantially flat top and bottom surfaces and a peripheral surface extending between the top and bottom surfaces. The peripheral surface includes a first portion intermediate the top and bottom surfaces and of a peripheral size greater than that of the top and bottom surfaces. Second and third portions extend from the first portion to the top and bottom surface, respectively. Each of the second and third portions has a peripheral dimension which decreases from that of the first portion to that of the top or bottom surface so that the surface of each of the second and third portions is angled away from the top and bottom surfaces, respectively. When the preform is engaged by the molds for making a disc the angled surfaces of the second and third portions serve to minimize if not eliminate the trapping of air and gasses along the surface of the record being formed which cause defects in the record surface.

Abstract: A method of manufacturing a protective and decorative molding for an automobile, comprising the steps of: adding a foaming agent to a starting resinous material comprising a vinyl chloride polymer or copolymer or a blend thereof; kneading the foaming agent and the starting resinous material; successively forming the kneaded mixture into an elongated rod or sheet blank by means of extruder or calender rolls; shearing the rod or blank into pieces having a predetermined shape; and molding the piece in a mold having high-frequency heating electrodes to apply a high-frequency voltage to the piece so that the foaming agent contained in the piece decomposes and foams to provide a product having a predetermined shape.

Abstract: A method of producing similar deep-drawn parts for double-walled structural parts having uniformly spaced walls and edge welding. During every deep-drawing procedure, a respective planar outer plate, which is placed upon the lower part of the tool, as is a filler plate, as well as a preformed or preshaped inner plate, which is placed over the tool punch, are shaped in common, whereby the preformed inner plate and the outer plate receive their final form or shape, and the filler plate is deformed into a preshaped inner plate for a subsequent deep-drawing procedure. The tool for carrying out this method is characterized in that the smallest spacing between the tool punch and the lower part of the tool corresponds to the entire thickness of the two inner plates and one outer plate.

Abstract: A multilayered preform is disclosed for making an open mouth container. The preform has a container-forming portion comprising a circular central area for making the bottom of the container, an annular sidewall-forming portion for the container surrounding add integral with the outer periphery of the central area, a flange connected to the annular portion, said flange having the contour of the rim of the container, said container-forming portion having a predetermined volume to meet dimensional requirements, and a retaining member having an enlarged portion. The preform is an improved structure that is readily adaptable for making containers from the so-called solid state pressure forming process.

Abstract: Novel resin products produced by reacting unique polycyclic, aromatic, polycarboxylic acid products with low molecular weight polyols display satisfactory toughness properties and good Barcol hardness values. The process for preparing these novel resin products first involves preparing an intimate, finely divided mixture comprising the acid product derived from the nitric acid oxidation of naturally occurring solid carbonaceous material, a roughly equivalent amount of a liquid polyol, and a suitable acid catalyst. The mixture is then subjected to a precure step which involves heating at temperatures between 80.degree. and 150.degree. C. for from about fifteen minutes to about four hours. The precured mixture may thereafter be subjected to suitable molding conditions at a temperature below about 220.degree. C.

Abstract: A decorative emblem is formed by producing a decorative surface, which may be printed and embossed, on a foil substrate. An integral bezel is then formed around the periphery of the decorative surface. Fluent plastic is cast onto the decorative surface to form a meniscus over it. Upon curing, the plastic cap gives a lens effect to the decorative surface. The decorative emblem may be adapted with several types of different attachment means, such as an edge adhesive strip, for fastening it to the intended surface such as an automobile, appliance, or other object.

Abstract: Conductor-clad composites are advantageously fabricated using molding compounds and associated processing techniques. The conductive cladding is applied and bonded to the composite during the molding process. The conductor-clad composite may be used as printed wiring board, and in this embodiment results in improved physical, chemical, mechanical, and electrical properties.

Abstract: The invention relates to a method of producing molded bodies of expanded plastic having a predetermined density, based on a starting material in granulate form to which a blowing agent and optionally a cross-linking agent have been added, said starting material being introduced into an injection molding machine/press in which it is heated and injected/pressed into a mold. In order to obtain an efficient production process without loss of raw material and a product whose density can be determined in advance, the material in the injection molding machine/press is heated to a temperature which is below the temperature required to initiate the reaction of the blowing agent/cross-linking agent, and the blank thus formed is subsequently transferred to an expansion mold having the shape of the desired final product, but larger, than the blank. The blank is caused to expand in the expansion mold and final expansion takes place outside the expansion mold.

Abstract: A method for making a centrosymmetrical spider of a universal joint by extrusion molding involves pressing both end faces of a cylindrical blank the same distance towards the center of the blank to force the blank material radially outwards from the center of the cylindrical blank in a stream which is symmetrical relative to the two end faces and into a cavity of a split mold.Also disclosed is a molding apparatus for practicing the method. The apparatus includes a floating mold. One end of the apparatus can be rigidly fixed to a press for operating the punches which provide the extrusion pressure.

Abstract: The green strength of elastomer blends of natural or synthetic cis-1,4-polyisoprene and synthetic elastomers is improved by adding to the chain of the synthetic elastomer an ionogenic compound. The said ionogenic compound can be incorporated into the chain of the synthetic elastomer through conventional polymerization with the monomers forming the synthetic elastomer, and the ionogenic group of the compound will be pendant from the chain or backbone of the elastomer. The ionogenic group is combined with a readily ionogenic metal base or salt. This combination yields blends which have greatly improved green strength as compared to rubber blends known to the art.

Abstract: In manufacturing a silicon nitride product of complex shape and uniform density, a mixture of silicon nitride in powder form together with a fluxing agent and a temporary binder is first produced. From the mixture a preform of substantially uniform density less than the density of the required product is then formed, the dimensions of the preform in the direction of subsequent hot pressing to the dimensions of the final product in the same direction being arranged to be in the ratio of the preform density to the required final density. The preform is then heated to remove the temporary binder and is hot pressed in a die carrying punches which together form a cavity defining the shape of the required product, the preform shape not conforming to the die cavity.

Abstract: A process for producing foam-shaped pieces having a poreless and smooth surface from particulate expandable styrene polymer which comprises the steps of heating not prefoamed particles of expandable styrene polymer to a temperature between 100.degree. and 170.degree. C. under a pressure of between 3 and 30 bar to cause melting of the polymer cooling the melt polymer to temperatures of about 10.degree. to 40.degree. C. above the softening point of the styrene polymer, enlarging the capacity of the mold in which the particles are melted, expanding the resulting mold melt material without supplementary external delivery of heat and thereafter cooling the mold to about ambient temperature followed by removal of the shaped foamed piece.

Abstract: Hollow articles such as bottles and containers are formed from tubular, elongated injection molded preforms made of thermoplastic material and having a finished neck portion adjacent an open end and a closed end body portion which method comprises annealing said preform by heating the portion of the preform body adjacent the neck to a temperature just below or about the Tg (glass transition temperature) for such material while maintaining the remainder of the preform body at a significantly lower temperature, for a sufficient time to essentially relieve the internal stresses in said body portion adjacent the neck, such annealing step being applied prior to the thermoforming of said preform into the hollow article.

Abstract: The present invention relates generally to improvements in plastic preforms adapted for telescopic association with a complementary smooth surfaced mandrel such as is used in conventional plastic blow molding machines. More particularly, the present invention contemplates a novel type of plastic preform as herein, which comprises an elongate hollow plastic member, the inner surface of which in the aggregate conforms generally with the shape defined by the smooth peripheral surface of a complementary mandrel. The inner peripheral surface of the hollow plastic member or preform below the rim portion presents a plurality of circumferentially spaced surface portions adapted for initial direct impingement with restricted areas of the peripheral surface of a complementary smooth surfaced mandrel, the spacing between the said surface areas of impingement providing passageways extending generally longitudinally throughout substantially the entire longitudinal extent of the plastic member.