Abstract: A roof tile making machine and its method of operation. The reinforcement ribs on the underside of a concrete roofing tile are formed during their manufacture by directing mortar into recesses in a pallet on which the tile is made, with a compactor means in the form of multi-tined wheels compacting the mortar in the recesses, and providing thereafter a secondary layer of mortar over the compacted reinforcement ribs, to complete the tile in a conventional manner. A tile provided by the apparatus of the invention has reinforcement ribs which are compacted to the same degree as the remainder of the tile, thereby ensuring that the finished product, when cured, has a uniform, or substantially uniform, strength.

Abstract: A method and apparatus for binding the fibers of, and forming a fiber reinforced plastic structure. A fiber reinforced plastic preform is created by depositing a mixture of reinforcing fibers, binding fibers and resin matrix fibers on a screen having a preselected geometry. The fiber reinforced plastic preform is exposed to high temperature fluid causing the binding fibers to melt and, thereafter, to cool air to temporarily bind the preform in a tackified state. The tackified preform is exposed to a higher temperature fluid causing the resin matrix fibers to melt and, thereafter, to cool air to solidify and thus bind and lock the reinforcing fibers of the tackified preform in place to create a homogeneous fiber reinforced plastic structure.

Abstract: A method of casting-masking-molding a thermoplastic resin product, includes the steps of placing a molding sheet 1 on an upper surface of a heated table plate 4, the molding sheet including a molding die 2, and a mask 3 including a plurality of mask constituting pieces 3a, 3b, 3c, ...

Abstract: The invention relates to a process of making a light weight, cementitious, three dimensional structure such as a building panel which includes the steps of measuring a quantity of water, measuring about 425 kilograms of cement, and between approximately 40 to 60 grams of ferric chloride in 40% solution by volume per approximately 278 liters of water, mixing the quantity of water, the cement and the ferric chloride, measuring between approximately 0.620 kilograms and 1.347 kilograms of substantially pure powdered aluminum, between approximately 0.230 kilograms and 0.710 kilograms of Hexafluorosilicate, between approximately 0.560 and 0.

Abstract: Compositions and methods for manufacturing sheets having a starch-bound matrix reinforced with fibers and optionally including an inorganic mineral filler. Suitable mixtures for forming the sheets are prepared by mixing together water, unmodified and ungelatinized starch granules, a cellulosic ether, fibers, and optionally an inorganic mineral filler in the correct proportions to form a sheet having desired properties. The mixtures are formed into sheets by passing them between one or more sets of heated rollers to form green sheets. The heated rollers cause the cellulosic ether to form a skin on the outer surfaces of the sheet that prevents the starch granules from causing the sheet to adhere to the rollers upon gelation of the starch. The green sheets are passed between heated rollers to gelatinize the starch granules, and then to dry the sheet by removing a substantial portion of the water by evaporation.

Abstract: Polymer composite products, including products made of polymer concrete, reinforced polymer concrete and reinforced plastics, such as bulk molding compound, sheet molding compound, mineral molding compound and advanced molding compound systems, are produced by the simultaneous application of vibration, heat and pressure to a mixture of filler and polymeric binder. The simultaneous application of vibration, heat and pressure provides a protective layer of polymerized binder that protects the surfaces of the mold and provides products that are substantially free of curling, cracking or voids. The process of the present invention substantially reduces the time required to cure polymer composite products.

Abstract: A process for making a mineral fiber artificial log that can be used in vented and unvented gas fireplaces, fireplace inserts, and free-standing gas fire room heater to simulate the appearance of a real burning log. The process utilizes a screen mold formed from a pattern that can be made to give the desired exterior configuration and size for the formed log. The screen mold is placed in an outer porous jacket and then in a vacuum chamber. A slurry of the formulation containing mineral wool fibers, a suitable high temperature binder, and water is drawn into the mold while contained in the vacuum chamber, so liquid is drawn through the mold and mineral fibers are trapped in the mold. The log is formed to the size and shape of the mold. Once molded, the log is removed from the mold, dried in an oven, treated with a suitable rigidizing exterior coating, and again oven dried. The log is painted suitably, dried again, and packaged for sale.

Abstract: A method of making a combination concrete panel wall, concrete window frame, and concrete sash glazing frame. The sill, lintel, and jambs of the window frame are fiber-reinforced concrete extrusions which are cut to length and cemented together. The hardened frame is placed in a concrete panel molding frame to locate and define a window opening. The concrete panel wall grout is then poured and dovetail-type mortise and tenon joints are precast in the exterior faces of the window frame which abut the poured concrete wall panel plastic grout, to permanently mold and interlock the window frame to the panel wall. The sash members are fitted about a window pane which is located in interior grooves in the sash members and then glazed. Sealing means interconnect the sash to the window frame to provide a condensation-resistant, water-tight, air-tight, heat and fire-resistant concrete wall closure.

Abstract: A novel process for creating aesthetically pleasing multicolor designs and patterns in cast materials, particularly cementitious materials, which may be used to imitate natural stone in appearance. The process includes the steps of preparing multiple colors of the casting material, geometrically loading these colors in a three dimensional array in a holding container according to formulas corresponding to particular patterns to be created, placing the geometrically loaded colors into a mold by means which include pouring, extruding and spraying, consolidating the mixtures in the mold and allowing them to set, and removing the cast structure from the mold followed by polishing and sealing if required. A removable matrix in the holding container provides the ability to reliably repeat patterns according to the loading formulas.

Abstract: A method is provided for manufacturing a balloon for a catheter. The method comprises the steps of providing a mold having a mold cavity that generally corresponds to an intended expanded form of the balloon. Securing elements are provided at opposite ends of the mold cavity for securing end sections of a tubular parison. The end sections of the tubular parison are twisted in opposite directions with respect to each other. The end sections of the tubular parison are secured in the securing elements, the parison is heated, and a pressure differential is created between the inside and the outside of the parison to cause it to expand into a balloon against the walls of the mold cavity. The previously twisted end sections of the parison result in the balloon transition sections having spiral ridges, allowing the balloon to be folded into a small diameter.

Abstract: A method of securing an architectural finish element to a surface ultimately formed by a castable material cast about a mesh material involves securing at least one projection to a backing surface of the architectural finish element such that the projection extends away from the backing surface. The castable material is then cast about the mesh material. The projection is then inserted into the castable material before the castable material has set, until the backing surface rests on the surface of the castable material, whereupon the projection co-operates with the mesh material to engage therewith. The castable material is then permitted to set about the projection, thereby firmly securing the projection in the castable material and securing the architectural finish element to the castable material and the mesh material.

Abstract: A method and apparatus for quickly and inexpensively providing a constant extrusion pressure for pipeline lining with a mortar. A mandrel is inserted in a pipeline section with a slug of mortar ahead thereof. A pushing force is applied thereto to overcome resistance to movement thereof. A constant tension pull is applied to the mandrel to effect relatively constant but effective extrusion pressure between the mandrel and the pipeline wall for extrusion of mortar on the inner wall of the pipeline section.

Abstract: In a method for quality control during production of concrete blocks by bringing a concrete mortar into an upwardly open hollow mold with a solid peripheral wall for forming at least one molded blank placed on a flat supporting surface, a thickness of a molded blank is determined contact-free for testing the dimensional stability. The volume of the molded blank is determined from the determined thickness and the cross-section of the hollow mold. The density is obtained from the weight and volume, which is a criteria for strength and resistance testing of the molded blank. Finally, the appearance of the molded blank is determined by at least one video camera and compared with the appearance of faulty molded blank to determine the molded blanks with surface errors. All results of the height, density and surface measurements can be used for control of the production arrangement.

Abstract: A method and apparatus for recovering concrete returned to the plant by delivery truck empties the delivery trucks into hoppers that dispense the so delivered left over concrete into molds designed to produce blocks of concrete suitable for regrinding into aggregate. The molded blocks are held in the molds for sufficient time to set the concrete for grinding before the blocks are separated from the molds. The molded blocks are then delivered to a grinding station where they are ground into aggregate of selected size for return to the concrete mixing operation. Any water that separates during the molding operation is subject to a settling operation to settle fine particles and the decanted water is then stored in a suitable reservoir for reuse, for example, in washing out the trucks.

Abstract: Containers use in the storing, dispensing, packaging, and/or portioning of food and beverage products. The disposable and nondisposable food and beverage containers are manufactured from aggregates held together by organic binders in order to be lightweight, insulative, inexpensive, and more environmentally compatible than those currently used for storing, dispensing, packaging, or portioning such products. The food and beverage containers of the present invention are particularly useful for dispensing hot and cold food and beverages in the fast food restaurant environment. The structural matrices of the food and beverage containers include a hydrated organic binder paste (formed by mixing the binder with water) in combination with appropriate aggregate materials, such as fibers to add flexibility and strength, glass spheres to make the product more lightweight and insulative, or clay to make the product extremely inexpensive yet strong.

Abstract: An enhancement composition and a method for its use in a molding process. The enhancement composition is applied to the interior surfaces of the mold cavity used in a molding process such as blow molding, injection molding, thermoforming or rotational molding. The enhancement composition is applied prior to closing of the mold and molding of the plastic article. The enhancement composition comprises a liquid carrier containing up to about 50 weight percent of enhancement solids which comprise a mixture of an enhancement solid such as particles of varied thermoplastic and thermosetting resins, metal flakes, glass beads, carbon, graphite, etc., and a binder solid which can be a hydrocarbon resin, wax, rosin or terpene base resin. The invention provides for almost unlimited modification of the surfaces of molded plastic products, offering the plastics fabricator the ability to mold products having very specialized surface properties with a low cost structural polymer, e.g.

Abstract: An improved process for forming a thin, durable coating of a perfluorosulfonated, salt- or acid-form ionomer on a selected substrate, which comprises contacting the substrate with an aqueous, surface active dispersion of the thermoplastic, sulfonyl fluoride precursor of the perfluorosulfonated, salt- or acid-form ionomer, contacting the dispersion-wetted substrate with a salt solution or a strongly ionizing acid solution of a sufficient ionic strength to cause a thin, adherent coating of the precursor particles in said dispersion to be formed on the substrate, then removing excess dispersion and excess salt or acid solution, annealing the coated substrate at an elevated temperature and thereafter converting the precursor to the desired acid or salt form ionomer.

Abstract: Laminar articles are manufactured by slush molding polyolefin compositions in powder form composed of:A) 10-40 parts by weight of a propylene homopolymer or copolymer;B) 0-20 parts by weight of a copolymer fraction containing ethylene, propylene and/or a CH.sub.2 .dbd.CHR .alpha.-olefin, the copolymer fraction being insoluble in xylene at ambient temperature and having an ethylene content equal to or greater than 80% by weight;C) 50-80 parts by weight of a copolymer fraction containing ethylene, propylene and/or a CH.sub.2 .dbd.CHR .alpha.-olefin, the copolymer fraction being soluble in xylene at ambient temperature and having an intrinsic viscosity in tetrahydronaphthalene at 135 C ranging from 1 to 1.4 dl/g.

Abstract: A spa having a one-piece, rotationally molded shell defining a reservoir for containing water including at least three sidewalls connected by an interior footwell, at least three exterior sidewalls, a coping interconnecting the reservoir sidewalls and the exterior sidewalls, and a floor beneath the reservoir footwell and interconnecting the exterior sidewalls. Water is circulated within the reservoir by a plumbing system which is disposed within an interior space defined between the reservoir sidewalls, the exterior sidewalls, the coping, and the floor; the plumbing system including a plurality of jets extending through the reservoir sidewalls; a plumbing harness; and a pump for circulating the water from the reservoir into the jets. It is also contemplated that a filter system and heating element may be provided and enclosed within the interior space of the spa.

Abstract: A method for lining a manhole: (i) inserting into the manhole a tubular liner wet with a curable liquid resin; (ii) everting an inflatable plastic bag into the tubular liner by charging water in it; (iii) closing the open end of the everted bag to form a closed space inside the bag; (iv) supplying compressed air to the closed space to cause the plastic bag to inflate and press the liner against the manhole; and (v) curing the liquid resin to harden the liner; and further improvements include: plugging the main pipe with two plugs to isolate the manhole and stop the drain from wetting the manhole, but providing a hose penetrating through the plugs to allow the drain to flow past the manhole; partially filling the portion of the main pipe isolated between the two plugs with a liquid absorbent filler; the tubular liner has varied thickness increasing toward its lower end stepwise or continuously and has its lower opening covered up by a net attached to the lower end circumference of the liner.