Abstract: An apparatus for cutting a honeycomb half-cell structure into sheets includes a blade for cutting the structure and a conveyor for positioning a length of the half-cell structure so that the blade cuts across the diagonal surface of the half-cell structure, thereby forming the sheets. The conveyor comprises platens including a plurality of bars contacting the valleys on one side of the half-cell structure and a space between each consecutive bar. The half-cell structure is cut along the diagonal surface alternating between one side of a first predetermined bar and one side of a second predetermined bar. A process for cutting a half-cell structure into sheets includes positioning a length of the half-cell structure so that the diagonal surfaces of the structure are positioned adjacent a blade for cutting and cutting across the diagonal surface to form the sheets.

Abstract: A laminate and a process for making a laminate of aluminum or aluminum alloy and a polyester. The process includes forming a laminate by contacting an aluminum or aluminum alloy sheet or foil with a film of polyester at a temperature and pressure sufficient to adhere the film to the sheet or foil, reheating the laminate to a temperature above the crystalline melting point of the polyester, cooling the laminate at a cooling rate controlled to prevent crystallization of the polyester, and quenching in water such that the molecular weight of the polyester layers in the laminate is between 14,000 and 23,000.

Abstract: The invention is a refastenable mechanical fastening system, made of free formed prongs joined to a substrate. The prongs taper and are nonperpendicularly oriented relative to the plane of the substrate. Each prong has in engaging means projecting laterally from the periphery of the prong. The free formed prongs are manufactured by the process of depositing liquid material onto a moving substrate, stretching the liquid material in a direction parallel to the plane of the substrate and severing the stretched material to form the distal end and engaging means of the prong. The advantageous usage of the fastening system in an article of manufacture, such as a disposable absorbent garment, specifically a diaper, is also disclosed.

Abstract: A storage or shipping carton for automotive parts or the like has disposed therewithin layers of resilient tubular dunnage having part configured cut outs in the side walls. The dunnage extends transversely of the carton between two of the side walls while the parts extend transversely of the dunnage between the other two side walls. The tubular dunnage is preferably formed of low density polyethylene and the notches in the dunnage are formed by flattening the dunnage and severing the side walls thereof while in the flattened condition and then reopening the dunnage to its normal configuration.

Abstract: An apparatus for manufacturing various shapes of bread that includes a device for forming a continuous sheet of bread dough, a roller for winding up the sheet of bread dough traveling on a horizontal conveyor from one of its sides into a bar of bread dough, the conveyor causing the bar to fall from its downstream end, and a cutter for cutting the falling dough body into dough pieces by squeezing it with flat surfaces of the cutter, according to its preset weight or length.

Abstract: A molding with the cross-section thereof varying in the longitudinal direction, the molding including a support strip; and a protector provided along the length of the support strip so as to bring the molding into contact with a window glass; the support strip including a mounting portion, an outer piece with the height thereof varying along the length of the support strip and a top portion for connecting the mounting portion and the outer piece; and the protector being integrally provided with the outer piece of the support strip at the lower portion thereof by extrusion molding.

Abstract: A method and apparatus for tipping surgical sutures which includes winding the suture around a drum while continuously monitoring the suture diameter in x and y directions and adjusting the tension on the suture to control the suture diameter as it is being wound. The drum is then placed in an apparatus which passes selected portions of the suture through a mist of cyanoacrylate tipping agent generated by ultrasonic atomization. The tipping agent quickly cures and the tipped portion of the suture may be cut to create a tipped end for insertion into a surgical needle to form a needle suture device.

Abstract: In order to guarantee substantially trouble-free operation when manufacturing sandwich elements on a double conveyor belt installation having a downstream cross cutter and cleaning device, the cleaning device disposed on a transport carriage i) is returned to the carriage of the cross cutter to pick up the next sandwich element, is braked and is then re-accelerated to a speed higher than the production speed, ii) is, after reaching a desired distance.

Abstract: An apertured thermoplastic fabric is formed by extruding, in the form of a film, a molten thermoplastic polymer having a secant modulus of no greater than 50,000 psi, embossing the film in a nip provided between a smooth surfaced roll and a patterned roll, wherein the patterned roll includes a plurality of discrete, raised projections disposed in a pattern and each of which includes a sharp distal end; applying sufficient pressure at the nip of the patterned and smooth surfaced rolls for causing a plurality of small apertures to be formed in the extruded film in substantially the same pattern as the pattern of discrete, raised projections; orienting the apertured film in both the cross-machine direction and in the machine-direction, and thereafter embossing the oriented film on at least one surface with a plurality of raised members spaced closer to each other than the spaces between the apertures in the oriented film, to thereby provide a matte-type finish on at least one surface.

Abstract: A process for making a refastenable mechanical fastening system, made of free formed prongs joined to a substrate. The prongs taper and are nonperpendicularly oriented relative to the plane of the substrate. Each prong has an engaging means projecting laterally from the periphery of the prong. The free formed prongs are manufactured by the process of depositing liquid material onto a moving substrate, stretching the liquid material in a direction parallel to the plane of the substrate and severing the stretched material to form the distal end and engaging means of the prong. The advantageous usage of the fastening system in an article of manufacture, such as a disposable absorbent garment, specifically a diaper.

Abstract: A method of forming an elongated decorative trim strip of thermoplastic material with an end of the strip having a desired shape of non-constant cross-section in planes perpendicular to the longitudinal axis of the strip. An extruded length of thermoplastic material is first made of a length substantially equal to the desired length of the decorative trim strip with a first longitudinally extending surface of the length being a front show face and a second longitudinally extending surface opposite the first surface being a back mounting surface. At an end portion of the extruded length, material is removed inwardly from the second surface to create a cavity behind the first surface while leaving the show face generally undisturbed.

Abstract: A process for producing lightweight, panel or block-shaped gypsum building materials with a pore structure, in particular wall panels, wherein calcium sulphate alpha-hemihydrate, water in a slightly more than stoichiometric quantity, setting retarders and/or accelerators and additives are mixed to form a pourable suspension and subjected to suitable forming. The ground calcium sulphate alpha-hemihydrate, having a Blaine specific surface area greater than 2000 cm.sup.2 /g, is combined if appropriate, with calcium sulphate beta-hemihydrate in a quantity of up to about 30% by weight relative to the calcium sulphate alpha-hemihydrate, and mixed before forming with a surfactant foam of a defined apparent density in the range from 40 to 80 kg/m.sup.3 and a uniform defined pore size, in a quantity for adjusting the apparent density of the gypsum building material to a defined value in the range from 300 to 1200 kg/m.sup.3.

Abstract: A method for making concrete roof tiles includes the steps of forming a continuous elongated ribbon or layer of concrete; cutting the continuous layer into a row of spaced end to end ribbon sections having a front edge and a rear edge; precompacting the front edge of one of two adjacent ribbon sections and compacting the precompacted front edge of the other ribbon section.

Abstract: A process for preparing a composite product from an intake material incorporating commercial, municipal or industrial waste containing organic, plastic and fibrous material includes first granulating and sizing the material. The material is then heated in three consecutive phases, first at a temperature sufficient to achieve an internal temperature within the material of about 215.degree. to 250.degree. F., then at a temperature sufficient to achieve an internal temperature within the material of about 250.degree. to 320.degree. F. and then at a temperature sufficient to achieve an internal temperature within the material of about 320.degree. to 400.degree. F., wherein said material is continuously mixed during said heat phases. The material may then be co-extruded with a reinforcement structure and forced into vacuum profile dies to form a product or compression molded to form a product and cooled.

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: Member of polymethylmethacrylate, polysulfone, polymer or a like material with a plurality of holes arranged in a predetermined, geometrical configuration. The holes are derived at through a procedure of repetitive drawing. Prior to the first drawing operation, each of the holes is filled with a material which is soluble to a certain chemical, yet drawable along with the base material. The member of material can be square, drawn to a reduced cross-sectional area as a square, the reduced cross-sectional members positioned with respect to each other and drawn again in a further operation, and repeated accordingly so that the cross-sectional area of each hole is reduced in proportion to each drawing step. Dependent upon the final drawing step, a subsequent member is provided which includes holes of a significantly reduced cross-sectional area. The member can be utilized as either a contact lens, an intracorneal inlay, an intraocular lens, a medical filter, or a like structure with small holes.

Abstract: An apertured thermoplastic fabric is formed by extruding a molten thermoplastic polymer film having a secant modulus of no greater than 50,000 psi, embossing the film in a nip provided between a smooth surfaced roll and a patterned roll, wherein the patterned roll includes a plurality of discrete, raised projections disposed in a pattern and each of which includes a sharp distal end; applying sufficient pressure at the nip of the patterned and smooth surfaced rolls for causing a plurality of small apertures to be formed in the extruded film in substantially the same pattern as the pattern of discrete, raised projections; orienting the apertured film in both the cross-machine direction and in the machine-direction, and thereafter embossing the oriented film on at least one surface with a plurality of raised members spaced closer to each other than the spaces between the apertures in the oriented film, to thereby provide a matte-type finish on at least one surface.

Abstract: A process for using shredded scrap or virgin fiber glass in combination with starch, water and other components to make ceiling tiles. The tiles are made by initially preparing a mixture of water, starch, boric acid and fire clay. That initial mixture is then heated to form a gel. Fiber glass is then added to the gel to form a pulp. The pulp is fed into trays to form slabs. The slabs are dried and finished into tiles.

Abstract: A method and apparatus for continuous casting of polymerizable materials that shrink during polymerization includes rapidly heating a moving matrix substantially uniformly throughout its cross section by radio frequency energy to initiate polymerization and maintaining the matrix thereafter in substantial thermal isolation such that substantially adiabatic polymerization occurs.

Abstract: A process and apparatus for manufacturing a frame with a groove such as a molding for use with a panel such as a windshield of an automobile. The process includes the steps of preparing a dummy panel having an outer configuration and a thickness equal to those of the panel, and continuously moving an extrusion port of a molding die means along the peripheral edge of the dummy panel so that a molding product is continuously formed along the peripheral edge of the dummy panel. The molding product is stripped from the peripheral edge of the dummy panel to obtain the frame with a groove. The groove is closely engageable with the peripheral edge of the panel. The apparatus includes a dummy panel having an outer configuration and a thickness equal to those of the panel, molding die means having an extrusion port, and moving means for moving the extrusion port of the molding die means relative to the peripheral edge of the dummy panel.

Abstract: A responder target for a magnetic detection system includes a signal element of high permeability low coercivity magnetic material such as permalloy or amorphous metal, and a control element of ferric oxide powder having the formula Fe.sub.3 O.sub.4 dispersed in a polymer binder. The ferric oxide powder having a coercivity H.sub.c in the range of 50-150 Oe and a particle size of 20-100 .mu.m, dispersed 20-35% by weight in the polymer binder. The ferric oxide powder in the binder is coated on a substrate to form a control element strip, laminated to the signal element, and chopped into lengths to form the responder target. Alternatively, the signal element strip is laminated to a support layer, and the ferric oxide is coated by extrusion over the signal element.

Abstract: The invention is a refastenable mechanical fastening system, made of free formed prongs joined to a substrate. The prongs taper and are nonperpendicularly oriented relative to the plane of the substrate. The prongs also have an azimuthal angle relative to the machine direction of the substrate. Each prong has an engaging means projecting laterally from the periphery of the prong. The free formed prongs are manufactured by the process of depositing liquid material onto a moving substrate, stretching the liquid material in a direction parallel to the plane of the substrate, severing the stretched material to form the distal end and engaging means of the prong, and imparting an azimuthal angle to the prong. The advantageous usage of the fastening system in an article of manufacture, such as a disposable absorbant garment, specifically a diaper.

Abstract: In the method for the manufacture of curved plastic pieces, such as brassiere underwires, the plastic pieces are formed from hot plastic material in a selected mold and are cooled to solidify the plastic material. In the improved method, a continuous thermoplastic wire in its thermoplastically formable state is coiled into a coil and simultaneously cooled thus forming turns of a solidified coil. The turns are subsequently cut along the axis of the coil over the entire length of the coil to produce the curved plastic pieces.

Abstract: Method of producing a single-phase composite structure of filamentary and non-filamentary semicrystalline morphology made from the same polymer, which is of a type capable of gelling in a suitable solvent and of being deformed into a high-modulus, high-strength product. Layers of the polymer in sheet form are interleaved with at least one layer, also of that polymer, made from filaments thereof. The method of making the product may involve heating a sheet of UHMWPE or other polymer gel (5% UHMWPE in 95% paraffin oil, by weight) to 125.degree. C., applying a knitted UHMWPE high modulus, high-strength structure on one side thereof, extracting the non-volatile paraffin oil therefrom with hexane, and evaporating the hexane.

Abstract: A method of manufacturing a randomly patterned floor covering having contrastingly-colored zones from a preform of rubber in which the preform is cut in pieces, each of which are molded into a blank having projections extending from a top side of the blank in relief-like fashion, solidified by vulcanization and then machined by cutting only in the region of the projections. The rubber forming the contrastingly-colored zones is mixed with contrastingly-colored particles in an amount of at least ten percent by weight. These particles are substantially free of flat surfaces and are in, at least, an advanced state of vulcanization. The particles located in the projections extending from the top side of the blank are exposed during the cutting step.

Abstract: Water-dispersible polyester fiber whose water-dispersibility is improved, and precursor filament tow are prepared by an improved process involving treatment of undrawn polyester filaments with a very small amount of caustic, when freshly-extruded, in a spin-finish.

Abstract: A thin-walled ferrocement product is formed from mortar supplied in a liquid or semi-liquid state, and a thin foraminous layer of reinforcement positioned centrally between the opposite wall surfaces of the product. The liquid or semi-liquid mortar is deposited in a uniform layer on a conveyor and the reinforcing material is positioned parallel to the lower surface of the conveyor. In a preferred embodiment, the material is maintained under tension at the desired position above the conveyor surface as the mortar is deposited onto the conveyor and flows through the foraminous reinforcing layer. The mortar is developed to a coherent plastic state before removal from the conveyor, preferably with the application of heat. The developed plastic material may be formed into various configurations, or may be maintained flat, while subjected to curing to a solid state. The developed plastic ferrocement material may be separated into convenient lengths for handling.

Abstract: A process for producing batches of a mouldable, fibre-reinforced thermoplastic material matched to a moulding to be produced and accompanied by heating, wherein quantities of an initial product of fibres and thermoplastic material-containing binder are intermittently moved into a preheating station, and intermittently moved therefrom through a melting channel as a strand and a matched batch is separated from the strand and supplied for batch further processing.

Abstract: A process for producing an optical recording medium, including the steps of: melt-extruding a resin to form a resin sheet; passing the resin sheet under pressure between a first roller having a predetermined unevenness pattern and a second roller disposed opposite thereto before the resin sheet is hardened, thereby to transfer the unevenness pattern to a surface of the resin sheet; and forming a recording layer having an organic coloring matter on the surface of the resin sheet provided with the unevenness pattern; wherein the steps are conducted while the resin sheet is moved.

Abstract: A process for producing thermoplastic resin products where granulated or particulate vulcanized rubber is sprayed by a heated heavy paraffin distillate composition to form a first intermediate mixture composition. The first intermediate mixture composition is passed through a heating chamber on a conveyor and combined with particulate thermoplastic scrap material in an approximating weight percentage of 30% thermoplastic material to 70% first intermediate mixture material. The combination forms a second intermediate mixture composition which is masticated in a masticator and extruded through a single screw feed mechanism for pelletizing and producing thermoplastic resin products which are useful for molding.

Abstract: Method for packing a measured quantity of thermosetting resin, intended for encapsulating a component such as an integrated circuit by introducing this quantity into a flexible plastics covering which can be sealed airtight, and packing for a measured quantity of thermosetting resin intended for encapsulating a component.

Abstract: A process for preparing a postformable composite article of a heat curable thermosetting polymer having a substantial length and a non-trivial uniform cross-sectional shape. The process includes controlling the pull rate and the temperature of the heating and cooling sections of the die in response to the viscosity and the cure kinetics of the thermosetting polymer composition and (2) the non-trivial shape of the article.

Abstract: Foam rubber articles may be prepared by shaping foamed latex into the desired configuration and gelling it. The gelled latex may then be cut to the required thickness to provide articles such as cosmetic puffs. The shaping process may use a disposable mold such as a circular polymeric casting or the mold may be permanent, such as glass, passing through a gelling chamber. The process reduces waste for products which has previously been cut from slab foam.

Abstract: Filter cartridge, in particular with a block-like shape, having a plurality of fold walls created by folding a permeable filter medium in a zig-zag fashion and which is provided with offsets formed by scoring so that a medium to be filtered passes through from one edge area of the zig-zag folding in the direction of the edge area of the folding on the opposite side. The offsets of adjacent fold walls which face one another contact each other as spacers and the filter medium is at least hardenable in the region of said offsets under the influence of heat. The permeable filter medium has fibres of thermoplastic material and the configuration of the fibres becomes more compact. The rigidity of the filter medium is increased by the welding of the filter medium under the influence of heat in the region of the offsets.

Abstract: An apparatus and a proces for the manufacture, by the extrusion method, of roof covering plates having at their underside a transverse flange shaped thereto. At a filling station cavities in the pallets corresponding to the transverse flange, are first filled with a hardenable plastic material such as fresh concrete, and said material is then compacted at at least one compacting station. Thereafter, a continuous layer of the material is deposited at a depositing station. The material is finally processed to roof covering plates.

Abstract: A process for consistently making ceiling tiles having uniform density and surface texture includes using a conveyor along which trays are moved in a generally horizontal direction. A feeder box is used to deposit pulp in the trays, the pulp being comprised of a mixture of water, starch, fibrous material, and other ingredients. The feeder box through which pulp is deposited in the trays is of a special design, and includes a sloping front edge which creates a negative rake angle with respect to layers produced by the system. The lower front edge of the feeder box includes a surface having a compound curvature. Ceiling tiles are produced by the process having improved uniformity of density and surface texture.

Abstract: Method for making blanks from a fragile, flexible material cast on a supporting strip and rolled to form a composite roll of the flexible material and strip. The method includes the process of separating the supporting strip from the flexible material, winding the supporting strip on a take-up roll and cleaning the flexible material before it reaches a station for blanking cards from the flexible material. The cards blanked from material are collected on a conveyor, while a remaining skeleton of the flexible material is collected for reuse in making the flexible material.

Abstract: An apparatus for producing molded articles attached to a flexible web by molding the articles in the cavity of a mold which includes entrances for the web and means for centering the web in the cavity. Elements are provided to trim waste from the molded article and automatically advance the web upon opening of the cavity. Elements are provided to separate articles with a predetermined length of web material attached.

Abstract: Processes for extruding thermoplastic coatings on substrates are provided by this invention. The processes include directing a substrate between two pressure roll means wherein one of the pressure roll means has a temperature less than the melting point of the thermoplastic. Next, the processes include providing a molten curtain of thermoplastic which is then directed with a current of a fluid medium, such as compressed air, so as to cause at least a first portion of the molten curtain to contact the first pressure roll means for a time sufficient to form a thermoplastic sheet. Next, the processes include extruding at least this thermoplastic sheet with the substrate between the two pressure roll means so as to form an extruded substrate having a thermoplastic layer which is separable from the substrate.

Abstract: Low density fibrous mats formed from fibres and thermosetting and thermoplastic binders, transformed by moulding at elevated temperatures are used for the production of mouldings. Such fibrous mats are produced in that a mixture of fibres and binders is spread out to form a fleece and the latter is compressed or compacted to a mat at high temperature. For the planned influencing of the characteristics of the moulding, while simultaneously reducing the binder requirement and the density, it is proposed that the fibrous mat or blanks thereof is passed through a pair of rollers with polished surfaces and by means of at least one roller binder is applied from the aqueous phase to the side of the fibrous mat facing the same under pressure action and that the fibrous mat is passed through the roller pair at a speed lower than the circumferential speed thereof and following onto the roller pair is passed through a drying zone.

Abstract: A method for preparing a perforated film, for use in the field of sanitary, food packaging and industrial materials, by thermally embossing an oriented polyolefin film with an embossing roll having a large number of protruding knobs and a pinch roll which presses the film against the knobs, and simultaneously taking up the resultant film at a rate not less than the processing speed of the embossing roll.

Abstract: A process for producing an information carrier containing recorded audio and/or video information wherein a web of a thermoplastic material is extruded onto the patterned surface of a metal master and pressure is applied to force said thermoplastic material into contact with the metal master. The thermoplastic material is cooled to a temperature below its softening point to form an imaged thermoplastic web which is separated from the metal master. Then a thin film of metal particles is deposited on the imaged surface of the thermoplastic web and said metallized thermoplastic web is laminated with a substrate carrying an uncured coating of a radiation curable resin. The resin is cured and individual information carriers are separated from the web of information carrying laminate. A center hole is placed in the separated individual information carriers, when appropriate.

Abstract: The present invention discloses a method for producing a multi-lumen needle suitable for administrating spinal anesthesia. The method will provide a needle that will allow the simultaneous administration of spinal and epidural anesthetic from a single site. A preferred needle made by this method can optionally be made with a stock configuration which has means for holding a catheter during the insertion of a spinal needle and is configured so as to provide gripping sites to assist in positioning the needle. The preferred needle of the present invention has a lumen which can serve as a spinal introducer. The introducer lumen sheaths the spinal needle until the spinal needle is in the epidural space. This assures that the spinal needle will not be bent or fractured in use by impingement with bone or hard tissue.

Abstract: When a film consisting of high density polyethylene and about three percent polystyrene is run on an interfolding machine to produce interfolded sheets of the film for use as deli wrap, the film is completely and consistently cut in the machine into sheets that are entirely separated from adjacent sheets. In comparison, sheets made from film consisting of 100 percent high density polyethylene are not consistently completely separated from adjacent sheets.

Abstract: A foamed and expanded low density polyethylene sheet or tube possesses both superior buoyancy and thermal resistance characteristics. The sheet or tube is made by a process including mixing a low density polyethylene with a blowing agent, surface activation agent and, preferably, a separation agent, heating the mixture at different temperatures to first melt the mixture and then gasify the blowing agent to expand the polyethylene cells, cooling the melted mass to partially harden and shrink the expanded cells, further expanding the cells by introducing a second gaseous blowing agent, cutting, extruding and cooling the expanded mass, forming a sheet or tube from the cooling mass, and finally cooling the sheet or tube for at least 24 hours. A buoyant, thermal resistant, water-repellent and moisture resistant sheet or tube results, which can be used, for example, as a liner for garments, including sports, business and military garments and other related equipment.

Abstract: The invention relates to a method of adjoining two ribbon ends to form a continuous loop of ribbon. This is done by aligning lengths of the ribbon and holding the same in taut condition. Subsequently, the aligned portions are welded to form a splice without cutting the excess portions of the ribbon. A separate cutter mechanism is employed to cut the excess ribbon portions.

Abstract: Elongate extruded sections of vinyl siding, having a top edge portion, which is intended to be hidden in use behind the bottom edge of an immediately higher section of siding, wherein the top edge portion is slit crosswise at a plurality of spaced apart locations, permitting freer expansion and contraction of the exposed portion of the siding with changes in temperature.

Abstract: A method and apparatus for producing molded articles attached to a flexible web by molding the articles in the cavity of a mold which includes entrances for the web and elements for centering the web in the cavity. Structures are provided to trim waste from the molded article and automatically advance the web upon opening of the cavity. Elements are provided to separate articles with a predetermined length of web material attached.

Abstract: A dispensable multilayer film having alternating layers of a ductile material, a brittle material, and optionally an intermediate layer. The film has excellent strength in its longitudinal and transverse directions but can be transversely cut by forces of less than 9 Newtons on the cutters of commercially available table top tape dispensers. At least one surface of the sheet material can be coated with a functional material.

Abstract: A catheter fabrication method and apparatus. Two rotating contact rollers define a nip to engage a mandrel used in fabricating an elongated tubular catheter. The rollers pull the mandrel from the catheter as a retaining block prevents the catheter from moving with the mandrel. The rollers rotate in opposite directions and are driven by a variable speed direct current motor.