Abstract: A method of forming an optical element on the surface of a substrate by ejecting a curable light guide forming liquid from a nozzle onto the substrate and curing the curable light guide forming liquid. A waveguide may be formed by moving the nozzle in a linear pattern over the surface of the substrate during ejection of the liquid from the nozzle. Curing the liquid may include exposing the liquid to ultraviolet radiation, and the radiation may be applied to only a small portion of the liquid. A multilayered waveguide may be formed by ejecting a further light guide forming liquid onto the first and curing it. A core and cladding may be formed simultaneously by ejecting core forming liquid from an inner tube and cladding forming liquid from an annulus about the inner tube. The waveguide may be formed in a groove, and a splitter may be formed by branching a second waveguide from a first, or by laying out two parallel waveguides and connecting them.

Abstract: The method for the fabrication of a curved back projection screen includes coating the screen before forming a sheet into the proper curvature. In one embodiment the sheet includes lenticulations to improve the perceived luminous intensity thereof. Through this method a back projection screen is provided that overcomes the manufacturing difficulties associated with previously known methods.

Abstract: A shift knob for use with automatic automotive transmissions has a one-piece body construction molded from a hard resin. The knob body is formed by gas injection molding, has a substantially uniform wall thickness and is covered with a soft resin. The knob body has a relatively thick bulbous grip portion at one end and gradually tapers to a slimmer lower end portion.

Abstract: A thin wall balloon for a balloon catheter is formed by depositing a film (such as polyimide) over a substrate which has an exterior surface configuration corresponding to a desired shape of the balloon in an inflated (or deflated) condition. After the polyimide film is cured, the substrate is removed from within the polyimide film by chemically dissolving the substrate.

Abstract: A method for preparing a molded product which includes (i) molding a fiber-reinforced plastic material in a mold, (ii) injecting a coating composition into the mold, the coating composition containing a vehicle component including urethane acrylate oligomer and epoxy acrylate oligomer as the main ingredients and a filler component including calcium carbonate as the main ingredient, and (iii) taking the coated molded product from the mold and plating the surface of the product. According to the present invention, there can be obtained a molded product having a plated layer with a satisfactory smooth and uniform glossy surface and having an improved adhesion between the molded product and the plated layer.

Abstract: A fiber preform constituting the fiber reinforcement of the part to be made is itself made by shaping and consolidating a fiber fabric by a liquid process. An interphase layer between the fibers and the matrix is formed on the consolidated preform prior to densification thereof with the matrix, such that the operation of densifying the consolidated preform can be performed without requiring supporting tooling therefor.

Abstract: A process for producing a cured composite and flexible light pipe, in which a molten cladding polymer and a crosslinkable core mixture are concurrently and coaxially extruded through a core mixture delivery tube of a coextrusion die, the extruded tubular cladding is filled with the extruded crosslinkable core mixture, and the crosslinkable core mixture is cured within the tubular cladding.

Abstract: A method of making a laminate and articles of furniture made from the laminate are disclosed wherein a transparent acrylic or polycarbonate sheet is coated with a clear urethane coating composition to at least a portion of one surface of the acrylic or polycarbonate composition sheet. The coated sheet is then treated with a water-based or latex color coating composition over the urethane coating. A urethane primer-surfacer coating composition is then applied over that portion of the sheet to which the color coating has been applied. The surface of the sheet is then adhesively bonded to a backing member, in which the uncoated surface of the acrylic sheet layer forms the outer layer of the laminated article. Preferably, the urethane coating composition is a low VOC urethane coating composition containing less than 4.0 pounds of volatile organic compounds per gallon of urethane coating composition.

Abstract: A method for forming a weatherstrip includes extruding a compound formed of 1-10 weight of polyglycidyl methacrylate having an epoxy group in the molecular structure thereof added per 100 parts of a rubber compound formed of SBR/EPDM. As the compound is extruded from the extruder, a urethane coating material is supplied to a nozzle to accomplish coating of an article concurrently with forming thereof. The extruded article is then vulcanized to assure good sealability.

Abstract: A method for producing carpet yarn produces yarn having substantial soil hiding, soil repelling and resistance to staining with acid dye characteristics. The yarn is made by forming at least one hollow trilobal fiber from a molten nylon polymer having an amine end group level below about 25 meq/kg, the fiber having a modification ratio of about 2 and a void volume of at least 3%; quenching the formed fiber sufficiently to solidify the molten nylon; immediately after quenching, at a yarn speed of at least 300 mpm, finishing the fiber with spin finish containing fluorochemical; fully drawing the finished fiber; texturing the finished yarn by a hot fluid texturing process; and subsequently, applying to the textured yarn a sulfonated stainblocker, the stainblocker being heated to at least 50.degree. C. and applied while the fiber temperature is at least about 100.degree. C. in the stainblocker application step.

Abstract: A tubular component made of composite material comprises a core of resistant fibers impregnated with a matrix of thermohardening resin. The core includes a tubular reinforcement made of fabric or of non-woven fabric. The tubular reinforcement comprises at least two coaxial adjacent layers which have reciprocal connection elements projecting radially.

Abstract: Moldings based on polyamides are surface treated with mixtures of at least 20% strength by weight aqueous hydrochloric acid with mono- or diethers of an aliphatic polyfunctional hydroxy compound in a mixing ratio of from 90:10 to 10:90% by volume.

Abstract: A mold (100) is constructed by forming a shell (125) having a back surface (127) and a mold surface (126) which defines a mold cavity (150), by forming a shell base (124) about the back surface (127) of the shell (125) so as to define an enclosed cavity (134) between the shell base (124) and the shell (125), and by filling the enclosed cavity (134) with substantially incompressible material (135).

Abstract: This invention relates to a process for manufacturing composites and laminates reinforced with continuous or long fibers and/or filaments. The process includes the subsequent steps of (a) forming a preform of reinforcing material by arranging a green tape, ribbon, sheet or cloth including a number of continuous longitudinally oriented fibers or filaments which are spaced from each other by uniformly distributed particles, bonded by a flexible binder, (b) removing or converting a major portion of the binder into matrix material and, if applicable, (c) filling the voids and cavities with matrix material. Further, this invention relates to a process for manufacturing composites and laminates reinforced with chopped-aligned fibers and/or filaments, which includes chopping a green tape or ribbon as defined above, mixing the chopped tape or ribbon with a binder, lubricant and/or matrix material and forming mouldings from this mixture by any moulding method.

Abstract: Method and apparatus for manufacturing a cable having a channel for receiving energy conductors, e.g. optical fibers, with a channel cover which has a weak bond with the material forming the channel to facilitate removal of the cover. The plastic material which provides the channel and the plastic material which forms the cover are simultaneously extruded around optical fibers in two flows which are separated in advance of enclosing the fibers and which join with a weak bond as the flows meet thereafter. In the apparatus, the extruder has a tubular element through which the fibers are fed and the tubular element divides the plastic material into two separate flows in advance of a die. The tubular member is adjustable in position with respect to the die to balance or equalize the plastics flow.

Abstract: Cohesive composite material is formed by forming a mixture of a melt of thermoplastic polymer and wood having a weight average particle size of about 0.1-0.5 inches in the X-axis, about 0.2-0.8 inches in the Y-axis, and about 0.5-1.5 inches in the Z-axis; shaping the resultant wood-filled polymer melt into a compressible shape; compressing this shape to establish additional intimate contact and bonding sites between the polymer melt and the wood disposed therein; and cooling the resultant compressed shape to solidify the polymer. The composites can be readily produced from abundant, low-cost recycled raw materials. Excellent cohesiveness is achieved, preliminary processing of the wood to introduce chemical functional groups therein is not required, and the composites can be readily worked by various techniques such as shaping, planing, sawing, surface grinding or polishing, and nailing, to yield highly decorative end products.

Abstract: A seamless belt is fabricated by application of a coating to an endless substrate. The substrate is elastically stretched over a hollow cylindrical elongated support mandrel. The mandrel is formed of a porous material. Fluid is applied under pressure through the mandrel to form a layer of fluid between the outer surface of the mandrel and the inner surface of the substrate. The flow of fluid is manipulated to axially displace and to rotate the substrate on the outer surface of the mandrel. The flow of fluid is manipulated to orient a selected portion of the surface of the substrate to an angle to a direction of application of a coating. The temperature of fluid is manipulated to assist in substrate temperature control at steps of the coating and drying process.

Abstract: A method for preparing hydrophobic fiber for processing, inclusive of crimping, cutting, carding, compiling and bonding, without substantial loss in hydrophobic properties in the finished staple or corresponding nonwoven product through initial application of a surface modifier component comprising one or more of a class of water soluble compounds substantially free of lipophilic end groups and of low or limited surfactant properties.

Abstract: A method employing a new use for acrylic latex caulk materials in fabricating durable dimensionalized configurations and background surfaces under room temperature conditions, for transfer to artistic and craft-oriented, artistic exhibition surfaces, is disclosed. The method is facilitated by a multilayered work surface specifically adopted for use in practicing the method. The method of the disclosed invention provides a mathematical relationship between the water fluid and the caulk material utilized in the method. This relationship is utilized to introduce these two components to create a slurry and to set up a precuring stage where the caulk material remains malleable for long periods of time. This provides the opportunity to more completely shape and form the treated caulk material to a desired, dimensionalized configuration.

Abstract: Hollow porous microspheres of uniform diameter and of uniform wall thickness are disclosed. The walls of the hollow microspheres comprise sintered together particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces. The interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface. The walls have uniform void content and the interconnecting voids are uniformly distributed in the walls of the hollow microspheres and the walls of the hollow microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions and bubbles. The hollow porous microspheres include microspheres in which the interconnecting voids have been closed and sealed.

Abstract: A process for manufacturing optical fibers includes extruding a transparent thermoplastic plastic sheet having plurality of transversely shaped and spaced parallel grooves extending in the longitudinal direction of extrusion. The thermoplastic sheet is rolled between polished rollers having upstanding circumferential ribs matching the shape and spacing of the grooves in the thermoplastic sheet. The rollers separate the extruded thermoplastic sheet into a plurality of elongated fibers and polish and cool the separated fibers. A preferred embodiment includes a first extruding die extruding said thermoplastic sheet having an index of refraction and a second extrusion die applying a co-extruded coating of plastic having an index of refraction lower than the index of refraction of the transparent sheet. The ribs of the polished rollers form various channel shapes that may produce optical fibers in both circular and non-circular cross-sectional shapes.

Abstract: Rayon/nylon and other sheath/core composite fibers or other materials, with good adhesion between sheath and core resulting from an adhesion promoter. The adhesion promoter is difunctional and sterically hindered. Fumaric acid and terephthalic acid are preferred adhesion promoters for the composite fibers or other materials, because each compound has both difunctionality and steric hinderance, allowing either to form covalent bonds to both the sheath and the core. Fibers produced in accordance with this invention may be used to produce fabrics which have the strength and wrinkle resistance shown by a number of synthetic fibers, but with the water absorption characteristics of natural fibers such as cotton.

Abstract: A film-forming polyester derived from a monohydric alcohol component having one or more long chain alcohols, the alcohol forming from 5 to 60% by weight of the components from which the polyester is derived. Coating compositions including the polyesters are particularly suitable for applying to cans before the cans are subjected to a spin-necking operation.

Abstract: An apparatus for forming a chamber member which receives optical light waveguides comprises an extruder head for extruding the chamber member followed by a calibrating device which inserts members into each of the chambers to insure the desired dimensions of each of the chambers and a method of using the apparatus by extruding a chamber member, allowing the extruded chamber member to cool and then calibrating the dimension of the chamber walls of the chambers.

Abstract: A method for covering at least one optical fiber with a protective layer comprises extruding the protective layer and embedding reinforcing elements in the protective layer to form a composite covering and simultaneously introducing the optical fiber into the composite covering. The method includes introducing a single waveguide or a plurality of waveguides, which may be formed into a bundle with a filling compound.

Abstract: Method for forming polyvinyl alcohol (PVA) into surgical elements include forming a mixture of PVA and water into a film by vacuum pressing with a first force, heating, applying a second force two to two hundred times the firs force, drying the film to remove water to a content of less than about 10% by weight based on the weight of the film, and molding the film into a desired shape.

Abstract: A method for producing a decorative panel wall paper and the like out of a flat piece of creaseable material wherein the piece is first creased along a multitude of crease lines to form a relatively flat production blank configured with a topography having peak portions and valley portions formed by regions of the piece between various ones of the crease lines, comprising the step of either spraying a sprayable pigment onto at least one side of the piece in an oblique direction so that the sprayable pigment impinges and is retained on windward sides of the peak portions with valley portions and leeward sides of the peak portions being shielded from the sprayable pigment, or immersing the piece into a fluid dip to coat the surface portions with a film operative to alter the appearance thereof and thereafter forming a relatively flat production blank.

Abstract: A method of making silver halide fibers involves reducing turbulence and friction during extrusion by moving an extrusion die in a direction opposite from flowing fiber and against a stationary preform arrangement. In another embodiment, the preform is doped with AgI or is a metal compound of the formula MY wherein M is selected from Li, Na, K, Rb, Cs; or MY.sub.2 wherein M is selected from Mg, Ca, Sr, Pb, Ba, Cd or Hg, and Y is selected from Cl, Br, or I. The resulting fiber has a more even core/clad interface with decrease in grain size to fiber surface and texture elongated along the fiber axis. This structure together with strengthening and stabilizing dopants, added to fiber material, gives decreased and stabilized optical losses and a higher elasticity of fibers.

Abstract: A process for producing an information recording medium comprising a substrate and provided thereon a recording layer and protective layer comprises the steps of forming on one substrate sheet a plurality of grooved preformats used for information recording mediums, forming a recording layer on the substrate sheet having thereon said plurality of grooved preformats, forming a protective layer on the substrate sheet on which said recording layer has been formed, and cutting the resulting substrate sheet into individual information recording mediums.

Abstract: A method for roughening the surface of a resin molded article to make it susceptible to metallizing is disclosed, including contacting a resin molded article at least the surface portion of which to be roughened mainly includes a block copolymer including 100 parts by weight of a polyarylene sulfide component block and from 100 to 200 parts by weight of a polyarylene sulfide ketone component block with a solvent capable of dissolving a polyarylene sulfide ketone more than a polyarylene sulfide.

Abstract: A process for producing a conductive supported yarn includes melt spinning non-conductive nylon filaments into a first set of filaments, separating at least one of the filaments from the freshly spun first set into a second set of filaments, providing the second set of filaments to a suffusion coating process so that the suffusion coated second set has a resistivity of between about 10.sup.6 and about 10.sup.9 .OMEGA./cm, and then recombining the first set and the second set to form a supported yarn.

Abstract: A gas-assisted injection molding article suitable for plating and a method for plating the article is disclosed. A sleeve is selectively mounted on an upstanding gas injection stud formed on the molded article. The sleeve seals an aperture which extends through the sidewall of the gas injection stud to the hollow interior of the molded article. The sleeve is preferably formed of a heat shrinkable thermoplastic. After the sleeve has been mounted to the article, the sleeve is subjected to a source of heat such that it retracts and is securely mounted to the gas injection stud. With the aperture sealed, the article can now be submerged in a suitable plating bath or other liquid medium.

Abstract: A polycrystalline diamond is prepared by chemical vapor deposition (step 101). A surface of the polycrystalline diamond is metallized (step 102). The metallized surface of the polycrystalline diamond is grooved with a YAG laser (step 103). A wedge or the like is driven into the grooves of the polycrystalline diamond to pressurize the same, whereby the polycrystalline diamond is divided along the grooves (step 104). Alternatively, a surface of a polycrystalline diamond prepared by chemical vapor deposition is grooved with a YAG laser (step 112), so that the surface of the polycrystalline diamond is metallized (step 113) after the grooving.

Abstract: A surface treatment method of a polyamide resin composition molded article is disclosed, comprising bringing the surface of a polyamide resin composition molded article into contact with water, said polyamide resin composition molded article comprising (C) 100 parts by weight of a resin composition comprising (A) from 10 to 80% by weight of a polyamide resin and (B) from 20 to 90% by weight of other thermoplastic resin; and (D) from 0 to 20 parts by weight of at least one modifier selected from a carboxylic acid having at least 2 carboxyl groups in the molecule or a derivative thereof, an amine containing at least 2 nitrogen atom in the molecular, urea or a derivative thereof, and a low-molecular weight polyamide. A coating method of a polyamide resin composition molded article is also disclosed, comprising, after bringing the surface of a resin composition molded article into contact with water, coating the surface with a coating composition.

Abstract: The present invention relates to a carbon fiber bundle includes a regular coil-shaped fiber bundle and having excellent stretch characteristic. A process for producing a coil-shaped carbon fiber bundle according to the present invention includes the steps of compositing at least two kind of pitches to spin them as single fibers, bundling the thus spun single fibers to form a fiber bundle, then infusibilizing the resulting fiber bundler under tension and carbonizing the fiber bundle.

Abstract: A method of producing a hydroxylapatite base porous beads filler for an organism, including mixing hydroxylapatite powder having particle sizes not larger than 125 .mu.m, in an amount ranging from 40 to 90% by weight, synthetic resin powder having particle sizes not larger than 74 .mu.m, in an amount ranging from 5 to 55% by weight, and resinous binder in an amount ranging from 0.5 to 5% by weight to obtain a mixture, granulating the mixture to form beads each having a diameter ranging from 0.03 to 25 mm, firing the beads at a temperature ranging from 900.degree. C. to 1180.degree. C. to form hydroxylapatite base porous beads, dipping the porous beads in a colloidal solution, removing air from the porous beads under vacuum, and filling the colloidal solution into the pores in the porous beads under pressure.

Abstract: A mattress of plastic foam material for medical purposes. The foam material is polyvinylchloride foam which has been coated with polyvinylchloride to create a completely seamless surface. Thus, the material is made impenetrable to potentially infectious body fluids which might be deposited thereon. In addition, the method of forming the entirely seamless surface prevents the accumulation of pathogenic fluids in various crevices which would otherwise be present in other types of seamless structures.

Abstract: In a method for the manufacture of stacked or wound type capacitors, made by the stacking and cutting out into unit blocks or by the winding of metallized polyethylene naphthalene films, at least after the stacking phase for the stacked type capacitors or the winding phase for the wound type capacitors, the capacitors are subjected to at least one annealing operation at a temperature of 240.degree. C. to 295.degree. C. for a period of at least one hour. The method can be applied notably to the making of chip capacitors for SMC mounting.

Abstract: A method of producing scintillation phosphor X-ray detector arrays using k materials and repetitive manufacturing techniques. The structures formed by this method may be used to detect x-rays, charged particles and neutral particles by converting the incident radiation into optical radiation. Detectors manufactured by the methods of this invention will produce better x-ray images and reduce the amount of radiation a medical patient or industrial target is subjected to.

Abstract: A method of preparing an in-mold label is described in which a resin film is embossed to form a gravure pattern having from 60 to 200 roll-formed lines per inch. The embossed film is stretched and then coated on its embossed pattern side with a heat-sensitive liquid resinous adhesive in an amount of from 1 to 10 g/m.sup.2 on a dry resin basis. The applied adhesive is then dried to form an adhesive layer on the film. The in-mold label obtained by the present invention is excellent in printing suitability including feeding properties and ink adhesion, has an advantage that die-cutting for producing the label can be conducted at a high efficiency, and is less apt to develop blisters even under a wide range of molding conditions when used in in-mold application.

Abstract: This invention relates to novel processes for preparing polypeptide solutions and spinning them into fibers. The process involves dissolving a polypeptide in a solvent system comprising lithium thiocyanate (LiSCN) and a liquefied phenol selected from the group consisting of phenol, m-chlorophenol, m-fluorophenol, and m-bromophenol or mixtures thereof. The solutions may be spun using certain wet spinning and dry-jet wet spinning methods. The process is especially useful for making silk fibroin fibers.

Abstract: A multilayer membrane for separating gas mixtures includes a polymer supporting membrane with a voids volume of more than 50% and a coating of two or more separating layers made of two or more different polymers. A hollow capillary serving as the supporting membrane is guided through the central bore of a spinneret. The spinneret has one or several concentric annular slits and/or annular grooves, through each of which a solution of one of the polymers forming the separating layers is applied to the supporting membrane. The spinneret terminates in a sealed chamber in which the solvent or solvents of the polymer solutions is/are evaporated and removed. The coated supporting membrane is drawn out of the chamber and wound up, possibly following aftertreatment with heat and/or liquids.

Abstract: Methods of coating stereolithographic parts and smoothing over characteristic surface discontinuities having alternating recesses and peaks. A stereolithographic part is first substantially covered with a substance capable of becoming less viscous when heated at a temperature which does not substantially thermally degrade the part, wherein the heated substance has an appropriate surface tension. Then, the substance is heated to that temperature until the substance flows preferentially into the recesses of the surface discontinuities and away from the peaked surface discontinuities. The substance will thereafter form a short surface connection over the recesses of the discontinuities through the surface tension of the heated substance. The substance is then polymerized or hardened either by cooling, thermally setting or by UV curing.

Abstract: The present invention provides a method of forming a free standing shape made of a material containing refractory metal, which entails providing a mandrel in a CVD enclosure, injecting a refractory halide gas and a reducing gas in the enclosure, reacting the gases in the enclosure to generate a material containing refractory metal, growing a layer of the material containing refractory metal on the mandrel and removing the mandrel to obtain the free standing shape, wherein the reducing gases is a silicon hydride gas or a mixture thereof.

Abstract: Method for making hollow microspheres of substantially uniform diameter and of substantially uniform wall thickness is disclosed. The walls of the hollow microspheres comprise sintered together particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces. The interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface. The walls have substantially uniform void content and the interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres and the walls of the hollow microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions and bubbles. The method includes heating the microspheres for a sufficient period of time to close and seal the interconnecting void.

Abstract: Flat continuous multifilament nylon apparel yarns suitable for critical dye applications and a process for making such yarns. The process for making the yarns includes spinning nylon polymer with a relative viscosity between about 35 and about 80 and stabilizing to make a feed yarn. The withdrawal speed in spinning is sufficiently high that highly uniform feed yarns are provided. In the process, feed yarn is drawn and subsequently relaxed, preferably in the form of a warp of yarns, so that the resulting drawn yarns have properties suitable for use as flat yarns and have excellent dye uniformity with large molecule acid dyes.

Abstract: Hollow porous microspheres of substantially uniform diameter and of substantially uniform wall thickness are disclosed. The walls of the hollow microspheres comprise sintered together particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces. The interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface. The walls have substantially uniform void content and the interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres and the walls of the hollow microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions and bubbles.

Abstract: Asymmetric hollow fibers comprising a fluoropolymer, and a process for making such fibers. The hollow fibers are useful for making fluid separation membranes, especially gas separation membranes. In one embodiment of the process of this invention, a polymer dope having a viscosity of about 3000 poise or greater is prepared by solvating the polymer in a solvent system containing about 40%-90% N-methyl-2-pyrrolidone and about 60%-10% propionic acid by weight. The dope is dry-jet wet-spun into hollow fibers using a water-NMP core solvent. The fibers are coagulated in methanol. The fibers are then coated with a highly permeable material.

Abstract: A method of manufacturing microspherules from activated carbon, including placing active-carbon particles of less than 100 .mu.m in size in a pelletizer equipped with a vortexer, incrementally adding an aqueous dispersion of a water-insoluble synthetic resin until microspherules of the desired size form, turning off the vortexer but allowing the pelletizer to continue operating, immediately powdering the microspherules off, and drying the microspherules.

Abstract: A thin wall balloon for a balloon catheter is formed by depositing a film (such as polyimide) over a substrate which has an exterior surface configuration corresponding to a desired shape of the balloon in an inflated (or deflated) condition. After the polyimide film is cured, the substrate is removed from within the polyimide film by chemically dissolving the substrate.