Abstract: A method of making a card which has a body having two main faces and at least one graphics element. A mold is provided having a mold cavity which defines the outside shape of the card body. A support element bearing a graphics element is placed in the mold cavity, and it is retained in place so that it remains substantially parallel to the walls of the mold cavity which define the main faces of the card body. A plastic material is then injected into the mold in such a manner that the plastic material occupies all of the space delimited in the mold cavity and not occupied by the support element. The part obtained in this way is then unmolded.

Abstract: A cast mold and process for casting a substrate for an information recording medium has an uneven preformat pattern formed on the mold surface. The uneven preformat features a pattern corresponding to tracking grooves and information pits, each information pit portion has a size with a length b in the direction parallel to the pattern of the tracking groove of 2 to 15 .mu.m and a width a in the direction perpendicular thereto of 1 to 6 .mu.m and a height c of 300 to 3500 .ANG.. The pit pattern has a pitch which is 1.8-fold or more of pit length b.

Abstract: A method for incrementally mold-forming sections of a fiber reinforced, thermoplastic material into a composite product which has a mold product configuration of non-uniform cross section and/or non-linear configuration. Large laminates are formed by utilizing small to medium sized molds to successively mold incremental sections of the total product. Each section of the laminate is first heated to a flowable condition and is then compressed within the mold cavity to form the desired incremental shape. This process is completed until all parts of the product have been formed utilizing variations in mold components to change geometries within the total part.

Abstract: A process for retarding the formation of incrustation on plant parts in contact with phosphating solutions in phosphating plants and where the working phosphating solution immediately after contacting the metal surface to be phosphated and while the solution is at its working temperature is caused to flow to contact an additionally presented solid surface that is disposed outside the region in which the workpiece metal surface and phosphating solution contact each other. The ratio of the second solid surface area which is contacted by the phosphating solution in the phosphating plant to the surface area of the plant parts in contact with the phosphating solution is at least 2.

Abstract: A segmented mandrel is adapted for use in fabricating large diameter, light weight articles (such as aircraft component structures) made of thermosetting composite materials by placing fiber on the external surface of the mandrel followed by autoclave curing of the composite materials. The segmented mandrel is composed of a center shaft extending lengthwise through the mandrel, four mandrel segments mating together along a seam between their respective adjacent edges, T-stiffeners for fastening the mandrel segments together, and bulkheads rigidly mounted around the shaft and connected to the stiffeners. This segmented mandrel is reusable, is easily assembled and disassembled, and has a system that creates a vacuum seal between mandrel sections while at the same time retains the functions of support and alignment of the mandrel segments carrying the parts being cured.

Abstract: A dual plastic compression formed shotshell casing includes an injection-molded annular-shaped hard plastic rim and an elongated compression-formed tubular body having an integral basewad portion at its base end which is mechanically interlocked with the rim to define the final basewad of the shotshell casing. In method of making the shotshell casing, the hard plastic rim is first injection molded independently. The tubular body is then formed in a two-step process. In the first step, a plastic preform is injection molded over the rim in mechanically interlocked relation to the rim. In the second step, the tubular body is compression formed from the preform mechanically locked to the rim.

Abstract: This is a process for fabrication of nickel-oxide insulation on a superconductor. The process utilizes; reacting oxygen-free nickel powder with oxygen-free carbon monoxide generally at 50.degree.-75.degree. C. to produce a nickel carbonyl, separating the nickel carbonyl from reaction by-products and excess reagents by cooling the carbonyl and decanting the nickel carbonyl liquor, and contacting the carbonyl to a surface of a wire containing superconductor or superconductor precursors in an atmosphere containing a controlled amount of oxygen, with the wire at 50.degree.-800.degree. C. to produce nickel suboxide insulation on the wire. The purified nickel carbonyl and oxygen may be alternately (rather than simultaneously) introduced, to deposit a series of metallic nickel films on the wire, each of which metallic films are then oxidized to a nickel suboxide.

Abstract: A process for die cutting a sheet of thermoplastic material imprintd with information or data of limited spatial displacement therebetween wherein the data is sequentially die cut in alternating rows and lines in a plurality of registered die cutting stations until all such pieces have been die cut generally in like sizes or pieces and wherein each piece is in residual attachment to the sheet of thermoplastic material.

Abstract: In a bicycle frame wherein a plurality of frame members are selectively joined together at the ends thereof, each of the joints which support the head tube, the seat and the crank housing is a lug joint consisting of a plurality of organic fiber layers partially wrapping the joined end portions of the frame members, the fibers composing each layer being oriented at different angles from the fibers in the adjacent layers, and all of these sheets being impregnated with resin which hardens to secure the sheets to the frame members. Web portions of these fiber layers also enclose a portion of the space between wrapped portions of the frame members, and each of these spaces is filled with a suspension of microballoons in hardened resin which cooperates with the web portions of the fiber layers to brace the joined frame members against movement toward each other during use of the bicycle.

Abstract: This invention relates to a process for converting hemicellulose of lignocellulosic material into a thermoset, water-proof adhesive. In one embodiment of the invention the thermoset, water-proof adhesive is used for converting other components of the lignocellulosic material into composite products such as panel products, reconstituted lumber and moulded articles without the use of any other adhesive binders which are an essential part of the conventional dry process of manufacturing composite products, such as wood-based particleboard, waferboard, medium density fibreboard, et cetera.

Abstract: An automotive body delivered in a direction, and covers such as an engine hood and a trunk lid and doors of the automotive body are opened and held in an open position. Thereafter, prescribed areas of the automotive body are coated, and those doors which are located downstream with respect to the direction in which the automotive body is delivered and those areas of the automotive body which correspond to those doors which are located upstream with respect to the same direction, are coated. Thereafter, the covers and the doors of the automotive body are closed.

Abstract: A method of manufacturing an elongated, multi-component structural member. A porous core is formed and a first layer of an air-tight skin is applied to the core. A second layer of peripherally extending fibers is applied to the first layer. A third layer of axially extending fibers impregnated with excess resin is applied to the second layer. A fourth layer of peripherally extending fibers which are resin-free is applied to the third layer and the resulting member is placed in a mold and cured. The excess resin from the third layer of fibers impregnates the fourth layer of fibers. An assembly of more than one core with fibers may be placed in the mold.

Abstract: A method for molding high temperature composites that transmits more uniform pressures to the surface of the composites. A compliant glass, glass-ceramic, or ceramic layer is caused to apply pressure to a composite precursor and heat is applied to the composite precursor to form a composite.

Abstract: A process for producing seamless metal-clad composite structures includes providing a hollow, metallic inner member and an outer sleeve to surround the inner member and define an inner space therebetween. A plurality of continuous reinforcing fibers is attached to the distal end of the outside diameter of the inner member, and the inner member is then introduced, distal end first, into one end of the outer sleeve. The inner member is then moved, distal end first, into the outer sleeve until the inner member is completely enveloped by the outer sleeve. A liquid matrix material is then injected into the space containing the reinforcing fibers between the inner member and the outer sleeve. Next a pressurized heat transfer medium is passed through the inner member to cure the liquid matrix material.

Abstract: A method for forming a part inserted in the auditory canal of a hearing impaired person, said part being either an otoplastic or a carrier part of the hearing aid insertable into the auditory canal or an ear adaptor member for a hearing aid to be worn behind-the-ear, characterized by providing an expandable elastic member, coating said elastic member with a hardenable material, inserting the coated member into an ear of the person who is hearing impaired, allowing the hardenable material to harden to retain the outside contour of the part. The elastic expandable member may be either a porous member which is partially saturated on the outer surfaces or may be a smooth member which is coated with the hardenable material. If desired, a physiologically compatible coating may be applied onto the hardened surface layer subsequent to the hardening process.

Abstract: An apparatus for manufacturing an otoplastic. An otoplastic is manufactured directly in the ear of a hearing-impaired person in that a deformable envelope is pulled over a die or over a shell or over an overlayed over-shell. This apparatus is then supplied with flowing otoplastic material between the die and the envelope, being supplied therewith in the ear. The envelope expands and assumes the shape of the auditory canal. After hardening or curing of the otoplastic material in the ear of the hearing-impaired person, the envelope and the die are removed and a module of either an in-the-ear or of a behind-the-ear hearing aid is integrated therewith.

Abstract: A process for forming flat plate ballistic resistant composites which includes impregnating a low-alkali magnesia-aluminum-silicate glass fiber woven roving with an impregnating composition. The impregnating composition includes a resin solution of a polyester resin in a polymerizable monomeric solvent a free radical catalyst and optionally, a thickening agent and further optionally a flame retardant material. The impregnated woven roving is cured in a molding unit at a temperature of about 225.degree.-255.degree. F. for a sufficient period of time and at a sufficient pressure to allow the impregnated woven roving to substantially conform to the mold unit. The temperature and pressure used are sufficient to maintain the exothermic temperature at about 300.degree. F. or below and to catalytically crosslink the polyester resin and monomeric solvent.

Abstract: Composite materials with matrices of tough, thermoplastic aromatic polyimides are obtained by blending semi-crystalline polyimide powders with polyamic acid solutions to form slurries, which are used in turn to prepare prepregs, the consolidation of which into finished composites is characterized by excellent melt flow during processing.

Abstract: A method of making an elongated structural element of fiber reinforced plastic material with a solid walled casing. A hollow tubular casing is generally simultaneously filled with elongated strands of continuous fibrous reinforcement and plastic material and solidified. The casing is part of the final product. An internal casing may also be used where the fiber reinforced plastic is between the internal and external casings. The elongated structural element may be initially shaped prior to solidification or after reheating reshaped into another shape such as a helical coil or spring.

Abstract: A method for the fabrication of a heat transfer member for use with electronic or microwave systems is described. The thermal heat transfer member is a generally planar composite member in which elongated high thermal conductivity fibers are disposed within a matrix material. The method involves molding epoxy matrix material along with conductive graphite fibers and filler material in predetermined geometries. The molded member is then formed in a manner such that the fiber ends are cleanly exposed at the surface of the member in predetermined locations. Metal caps may be formed over the fiber ends to improve heat transfer. Heat is transferred into the member, along the commonly directed fibers, then out of the member at a heat output surface.