Abstract: A process of forming a soft and resilient web exhibiting a substantially continuous pattern of debossments or apertures is disclosed. The process comprises locally heating process to melt predetermined points of the web. The process includes: continuously bringing the web in contact relation with a forming structure exhibiting a substantially continuous pattern of apertures corresponding to the debossments or apertures of the web; locally heating the region of the web at the predetermined points along the surface of the web by an energy source to give the web temperature above its melting temperature; applying a substantially uniform fluid pressure differential to the locally heated web at least in those areas to be debossed or apertured, whereby the web is debossed or apertured at the predetermined points and generally maintains its surface structure at least in those areas in which the web is not debossed or apertured; and removing the debossed or apertured web from the forming structure.

Abstract: A method for preparing a mold form includes forming a mold blank having a surface corresponding to the surface of the article desired and enclosing the mold blank in an open ended enclosure. A thin layer of polymer resin, preferably polyurea is sprayed on the surface of the mold blank and allowed to cure. Heat transfer tubing is inserted over the resin layer. A mixture of metallic pellets and epoxy are inserted over the heat transfer tubing and then another layer of resin is sprayed over the mixture. After the resin has cured, the mold blank is removed to expose the mold form having an outer surface of polyurea.

Abstract: An improved encapsulation method is proposed for the encapsulation of a substrate-based package assembly, which can help to prevent mold flash over exposed package surfaces after encapsulation process is completed. The proposed encapsulation method is characterized by the forming of a cutaway portion in a solder mask over the substrate along a seam line between the solder mask and the molding tool that would exist between the solder mask and the molding tool when the semi-finished package assembly is fixed in position in the molding tool. During encapsulation process, the cutaway portion defines a constricted flow passage to the injected encapsulation material; and consequently, when the encapsulation material flows into this constricted flow passage, it would more quickly absorb the heat in the molding tool, thereby increasing its viscosity and retarding its flow speed.

Abstract: A method of manufacturing a microdialysis catheter, comprises the steps of extruding a flexible material to form an elongate catheter body having a substantially cylindrical outer surface and a plurality of continuous internal channels extending in the longitudinal direction of said catheter body; sealing a free end of said catheter body; providing in said surface at a distance from said free end an opening extending into said catheter body to communicate with a portion of a first of said channels; providing communication between said first channel and a second of said channels at a distance from said free end shorter that said distance; and covering said opening by a microdialysis membrane.

Abstract: A rustication for preparing reveal bands in a precast panel surface. The rustication is made from a one piece elongate body of extruded foam and comprises an upper surface, a lower surface and laterally-spaced sidewall surfaces that extend between the upper and lower surfaces. The lower surface defines a base plane. One or more downward-extending edges that project below the lower surface base plane are included such that they can bend under the application of a load, such as when concrete is poured around it to form the precast panel. Under such a load, the edge scrapes along the top of a panel-forming surface so that an enhanced sealing engagement between the panel-forming surface and the rustication is effected. The rustication can further include a plurality of longitudinally-spaced apertures that extend from the upper surface to the lower surface to facilitate the securing of the rustication to the panel-forming surface, thereby precluding rustication shift once the concrete is poured.

Abstract: A plastic net consisting of a pre-stretched plastic stretch film comprises pre-stretched bridges (7) and filaments (6), said filaments extending in a main direction (5) and being transversely folded in order to increase their tensile strength. The required reshaping of the original film material is performed by a pre-stretching device (9) with interacting rollers (10, 11) and a transverse folding device (20) with a reshaping area (23) in which the width of the filaments (6) is reduced.

Abstract: The present invention relates to a method of producing micro and nano-porous polymeric articles with well-defined pore structures.

Abstract: A mold plug for use in a mold, the mold being used in a rotary concrete casting process to make a cast article, the mold plug comprising: a rigid internal core having an internal engagement means to secure the plug in the mold during casting and to facilitate removal of the plug from the cast article after casting is complete; and a pliable external cover on the internal core, the external cover having a surface adapted to not bond with concrete, and having a predetermined size and shape, wherein, when the mold plug is removed from the cast article after the casting is complete, a hole of a predetermined size and shape is left in the cast article.

Abstract: A trim panel (1) and a method of making a trim panel (1) comprising providing a formable sheet (12) having at least one layer, locating the sheet (12) adjacent to a forming surface (80), conforming the sheet (12) to the forming surface (80) so that the sheet (12) has a characterizing topography (15) and removing the sheet (12) from the forming surface (80). A substrate (40) is provided having a rear surface (45) and an opening (55) therethrough. Lastly, the sheet (12) is attached to the rear surface (45) of the substrate (40) so that the characterizing topography (15) extends through the opening (55). Alternatively, the sheet (12) may comprise at least one tab (17) and the substrate (40) may comprise at least one tab opening (57) wherein the tab (17) is inserted into the tab opening (57) to snap-fit the pieces together.

Abstract: A method for making a spiral fuel body for a layered candle is disclosed. Layers of a non-liquid candle fuel are successively poured into a mold and cooled to a non-liquid state. The layers bond together in the mold, and are removed as a sheet of candle fuel, which is rolled into the spiral fuel body. Each layer is distinguishable from the other layer for the life of the candle by color, aroma, and thickness. A mold that can be used for making a rolled candle has obtuse sides for producing a tapered form to the candle.

Abstract: A panel-forming system including a plurality of bulkheads and one or more extensions. A first group of the bulkheads are used to define the overall dimensions and shape of the panel, while a second group are used to define at least one aperture formed into the panel. The extensions are made up of a bulkhead-engaging portion and a recess portion that extends from the bulkhead-engaging portion. The aperture extensions are configured to allow various-shaped recesses to be formed in the panels adjacent the apertures. In accordance with 37 CFR 1.72(b), the purpose of this abstract is to enable the United States Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract will not be used for interpreting the scope of the claims.

Abstract: A peripherally encapsulated product, such as an oven door outer shell, is molded in accordance with this invention by placing a piece of glass between mold clamping portions of relatively movable closed bodies when the latter are in an open position. Preferably both bodies are heated and thermosetting polymeric material (SMC or BMC) is placed upon selected areas of one of the mold bodies within and about an area corresponding to an annular mold cavity and outboard of a peripheral edge of a piece of glass. The glass is clamped between mold clamping portions of the mold bodies which are then progressively closed creating compression forces which extrude the thermosetting polymeric material into the annular cavity and into complete encapsulation of the continuous peripheral edge of the piece of glass. The thermosetting polymeric material is cured, the mold bodies are opened and the product is removed therefrom.

Abstract: A fiber preform constituting fiber reinforcement of a composite material part that is to be fabricated is made by superposing and bonding together fiber plies, and by densifying the needled preform by introducing a material constituting the matrix of the composite material into it. During the process of making the preform, a powder is dusted onto the surface of at least some of the plies, the powder comprising at least one ingredient selected from a solid resin in powder form and solid fillers in powder form. The powder is dusted onto the surface of the top ply of the preform that is being made, prior to superposing and needling at least one additional ply.

Abstract: A method and an apparatus for cutting a laminate made of a brittle material and a plastic with a cutting tool is described. The plastic is heated up, thereby lowering its viscosity, at least in the region of a predetermined cutting line. A cutting tool is placed onto the plastic side of the laminate, the loading pressure being adjustable. By moving cutting tool relative to the laminate along the predetermined cutting line, the plastic is severed; at the same time the brittle material is scored, thereby inducing a mechanical stress. If appropriate, the mechanical stress along the cutting line is subsequently increased to exceed the rupture strength of the scored brittle material. A preferred application is the cutting of thin glass or glass-ceramic/plastic laminates.

Abstract: The invention relates to a device on a handheld cutting or sawing machine with a rotatable cutting or sawing blade; a driving machinery for rotating the blade; means for supplying cooling or flushing water on the blade and/or a workpiece; a rear handle with controls for the driving machinery; a front handle bow with a front part (5) which is the normal gripping part of the handle bow; a right hand side part (6) and a left hand side part; and a water valve (8) for control of the flow of cooling or flushing water, said valve comprising a valve housing (27) with a valve house chamber (33); a valve body (36) which is turnable about an axis of rotation (23) by means of a lever (22); an inlet nipple (15) for the connection of a water hose (16) for incoming water to the valve; and an outlet nipple (17) for the connection of a water hose (10) for outgoing water from the valve; and securing means (35, 43) for mounting the water valve on the handle blow.

Abstract: The apparatus for cutting a laminate, which is made of a brittle material and a plastic, has a cutting tool for severing the plastic along a predetermined cutting line and simultaneously scoring the brittle material; a heating device for heating the plastic along the cutting line; a device for pressing the cutting tool with an adjustable pressure on the laminate; a device for moving the engaged cutting tool along the cutting line to simultaneously sever the plastic and score the brittle material and a controller for controlling the heating device so that during the severing and scoring a temperature of the cutting tool is maintained constant and the heating is sufficient to lower viscosity of the plastic along the cutting line so that a predetermined loading pressure of the cutting tool on the laminate necessary for simultaneously scoring the brittle material and severing the plastic is not exceeded, whereby uncontrollable fracture of the brittle material does not occur.

Abstract: A headliner (10) for use with a motor vehicle including a combination of a chopped fiber roving (22) bonded between a non-woven film layer and a urethane core (14) to eliminate warpage in the headliner (10) after the molding and forming process is complete. The combination of stiffness and mechanical bond provides this effect. The combination may also include a polypropylene non-woven material (18) combined with a polyethylene film (20) to form a laminate top (12) and bottom layer (16). The chopped fiber roving (22) is randomly disposed between the laminate (21) and a urethane matrix (44) used to form a core (14) of the headliner (10) to provide the shape stability to the headliner (1).

Abstract: A method for producing a zipper for use in the production of reclosable plastic bags of the type having the zipper extending across a top end of the bag. The zipper has a first profile member and a second profile member that is interengageable with the first profile member. At bag length intervals of the zipper notches are formed by removing at least a portion of the first profile member and a portion of said second profile member. A mold is positioned about each of the notches and a molten thermoplastic material is introduced into the mold cavity filling the notch and extending beyond the notch and over the zipper top so that when the molten thermoplastic material is cooled an end stop is formed in situ at each of said notches.

Abstract: A method of controlling a compression injection molding machine having a movable die mounted on a movable die plate including using a pressure sensor to detect a reaction force produced at the movable die by resin being injected into a die cavity. The pressure sensor is positioned between the movable die plate and a housing supporting a toggle driving mechanism that moves the movable die plate and movable die. The output of the sensor is applied to control the injection of the resin into the die cavity or the thickness of the resin. This output can also control gate cutting or resin injection speed.

Abstract: A peripherally encapsulated product, such as an oven door outer shell, is molded in accordance with this invention by placing a piece of glass between mold clamping portions of relatively movable closed bodies when the latter are in an open position. Preferably both bodies are heated and thermosetting polymeric material (SMC or BMC) is placed upon selected areas of one of the mold bodies within and about an area corresponding to an annular mold cavity and outboard of a peripheral edge of a piece of glass. The glass is clamped between mold clamping portions of the mold bodies which are then progressively closed creating compression forces which extrude the thermosetting polymeric material into the annular cavity and into complete encapsulation of the continuous peripheral edge of the piece of glass. The thermosetting polymeric material is cured, the mold bodies are opened and the product is removed therefrom.

Abstract: A method of constructing large, unitary, fiber-reinforced Polymer composite containers using a vacuum assisted resin transfer molding process. The method allows for the construction of container systems with only two separately molded parts—an open box consisting of a base (i.e., floor), 2 sidewalls and 2 endwalls, and a cover (i.e., roof). The method results in a structure which maintains the continuity of the reinforcement fibers across the junction between the floor, side, and end walls corners. This method can be applied to very large composite structures such as railcar bodies, intermodal containers, and shelters.

Abstract: Processes for producing durable three-dimensional bowls such as water basins comprising plastics preferably acrylics heavily filled with alumina trihydrate, some embodiments including visible particles such as those sometimes used for simulating nature stone. A preferred process for manufacturing the bowls of such material includes defining a flat rigid blank such as from a larger rectangular bulk sheet in the approximate top outline shape of bowl to be formed, e.g., the blank being oval for an oval bowl and circular for a circular bowl. The blank is provided a smooth side which will be the concave finished and exposed side in use. The blank is heated to a point of softening and of uniform temperature throughout, located within a molding die such as a matched molding die having a female cavity of the desired bowl shape, indexed to the die, but left generally unrestrained so that the heated blank and un-clamped edges thereof are allowed to draw inward to reduce tension loads during forming.

Abstract: A flow tube for an induction system with a turbo charger includes a first tube half and a second tube half with a noise attenuation plate positioned between the halves. The noise attenuation plate includes a plurality of holes having varying diameter and depths. The first tube half, the second tube half, and the noise attenuation plate are integrally formed as a single piece during an injection molding process. The noise attenuation plate is folding along a first living hinge to overlap one of the first or second tube halves. The other of the first or second tube halves is folded along a second living hinge to overlap the noise attenuation plate forming a flow tube that defines a flow path. The noise attenuation plate is thus positioned in the flow path. When acoustic energy created by the turbo charger encounters the noise attenuation plate, the change in impedance results in acoustic reflections back toward the turbo charger.

Abstract: A process for rendering films, film composites, and articles made therefrom less resistant to passage of water vapor by passing a filled precursor film or film composite through the nip of interdigitating grooved rollers. The films or film composites are generally formed using a precursor film of a film forming polyolefin or polyolefin blend, with a relatively high filler loading and optionally an elastomer. A process is disclosed for making diapers or other disposable items where a relatively high water vapor is coupled with a resistance to liquid strikethrough.

Abstract: A method of manufacturing ceramic bodies comprising the steps of: preparing a ceramic sheet; forming through holes in the ceramic sheet, each of the through hole forming at least one part of the contour of each ceramic bodies; and cutting the ceramic sheet into pieces of ceramic bodies. The ceramic sheet can be a single ceramic sheet or a laminate of ceramic sheets. The method of manufacturing ceramic bodies further comprises a step of forming a recess in the ceramic sheet, or pressure molding or partially removing of the ceramic body, as required. The manufacturing method provides inexpensive production of small ceramic elements having a complicated shape and extremely smooth surfaces with less uneven filling and nonuniform density.

Abstract: The invention relates in particular to a facia panel designed to make it possible for an airbag to pass through it at the time the airbag is inflated. In accordance with the invention, the part includes a plastic support element (8) having a reduced thickness in comparison to its other dimensions; a connecting sheet (6) joined to the support element; the part presenting a special zone (15) which forms a door and is designed to make it possible to create a passageway, the zone being delimited by a periphery constituted by an embrittled portion (14) presenting two extremities of an articulating portion which defines, between the two extremities, an articulation axis overlapped by the sheet; along at least the major part of the embrittled portion, the sheet is present on either side of the embrittled portion; and the sheet is present over the greater part of the special zone.

Abstract: A method for processing a film. The method impressing the whole surface or a selected surface of the film to form protuberant structures on the film by using a transfer and an impresser which has grain projections formed thereon, wherein the protuberant structures have a protuberant shape with an opening hole on the tip or without an opening hole on the tip.

Abstract: A rear trunk for a vehicle having a rear wall which is inclined with respect to a bottom portion of the trunk such that it overhangs the bottom of the trunk. The opening of the trunk may be narrower than the bottom of the trunk without requiring complicated manufacturing steps. The body of the trunk can be formed in this shape as an integral piece by blow molding. An inner member can be included which divides the interior space of the trunk body into separate compartments, and may be blow molded integrally with the trunk body.

Abstract: A rustication for preparing reveal bands in a precast panel surface. The rustication is made from a one piece elongate body of extruded foam and comprises an upper surface, a lower surface and laterally-spaced sidewall surfaces that extend between the upper and lower surfaces. The lower surface defines a base plane. One or more downward-extending edges that project below the lower surface base plane are included such that they can bend under the application of a load, such as when concrete is poured around it to form the precast panel. Under such a load, the edge scrapes along the top of a panel-forming surface so that an enhanced sealing engagement between the panel-forming surface and the rustication is effected. The rustication can further include a plurality of longitudinally-spaced apertures that extend from the upper surface to the lower surface to facilitate the securing of the rustication to the panel-forming surface, thereby precluding rustication shift once the concrete is poured.

Abstract: A method for medical balloon fabrication comprising the steps of securing a balloon with a mold by inflating it and then enlarging the inner diameter of the balloon. The devices of the invention comprise a fixture with a mold configured to hold the inflated balloon and a drill that can be centered with the mold to enlarge the inner diameter of the balloon.

Abstract: A method for making a friction damper for linen washing machines which have a damper rod that is telescopically driven inside a mantle, and at least a friction element, arranged between said rod and mantle and housed in a housing cavity therefor. The method is based on a first molding step for molding a friction damper casing having a hole for housing said rod and a friction element housing cavity, and a second operating step for making, in said cavity, a plurality of restraining undercut portions for restraining said friction element.

Abstract: The disclosure is for a method and apparatus for constructing a concrete wall with a single pouring of concrete. The mold for the pouring of the wall is formed essentially of plastic foam insulation which remains attached to the finished wall to serve as thermal insulation. The wall structure is therefore self jigging and requires no elaborate mold structure or any time or labor to remove the finished wall from the mold.

Abstract: A disk molding apparatus is provided with: a fixed die; a movable die that presses a molten resin material filling a cavity formed by the fixed die and the movable die to mold a disk and punches a central part of the disk to bore a hole; a control device that controls a reciprocation of the movable die in a thickness direction of the disk; and wherein a projection for punching the central part of the disk is formed on a mirror plate of the movable die integrally with the movable die.

Abstract: Apparatus (1) for monoaxial stretching of a synthetic film (2) under tension using a roller arrangement in which there are at least two stretching rollers (3) defining a stretching gap (4), where, in order to produce a breathable synthetic film (2) by means of tensile strain, the stretching rollers (3) for the cold-stretching of the synthetic film (2) have surfaces which increase the coefficient of friction.

Abstract: An apparatus for sealing at least a portion of the urinary tract to prevent the unwanted discharge of urine includes a body member with a tubular member, encircled along its length by an overcoat layer, that encases a fluid, forming a cavity. The body member, with its tubular member and overcoat layer are elastically deformable from an initial “rest” or “relaxed” state, when outside of the body, where at least a portion of the overcoat layer is of a diameter equal to or greater than that of an undilated urethra. A stylet may be placed into the tubular member to serve as a guide, for elongation of the body member and to provide rigidly to the body member upon insertion into the urinary tract. There is also disclosed a method for making the apparatus of the present invention.

Abstract: A method of making plastic containers having walls with fluid circulatable channels integrally formed therein comprises the successive steps of injecting a molten thermoplastic material in a mold cavity having a channel configuration to define, in the container being mold, walls with thicker portions defining a rib configuration, injecting a pressurized fluid throughout the rib configuration to displace molten material therein and to form a hollow channel therein, cooling the container being mold removing the molded container from the mold and cutting through the hollow channel at two spaced locations to form inlet and outlet openings to the channel to thereby enable circulation of a fluid through the channel.

Abstract: An optical recording head is provided which includes a slider body having a leading edge. A void is formed in the slider body to receive a sphere of optically transparent material. The sphere is inserted into the void such that a portion of the sphere protrudes from the slider body. The protruding portion is lapped to be coplanar with a surface of the slider body to form a near-field lens. A mesa may be formed onto the lapped portion and may include a coil. The slider body, mesa, near-field lens, and coil may be formed in one batch process.

Abstract: A method is provided for producing porous hydrophilic materials whereby nonporous materials are subjected to ester hydrolysis to generate site-specific perforations. Processes for separating aqueous phase from organic and aqueous mixtures utilizing the invented materials also are provided.

Abstract: A method of performing a uniform illumination pattern in a back-light plate using sand-blasting process. This method mainly includes two steps. The first step is to perform a manufacturing process, for example a chemical etching process or a laser-cutting process, to form a hole mask on a metal plate with a predetermined hole pattern. The second step is to position the hole mask of the metal plate on one illuminating face of the back-light plate to perform a sandblasting process. A plurality of recesses, each being no deeper than a predetermined depth, are consequently formed to serve as a uniform illumination pattern of the back-light plate. When visible light emits into the back-light plate, the plurality of recesses on the illuminating face make the emitted visible light uniformly illuminated.

Abstract: A microneedle array is manufactured using a mold preparation procedure that begins by placing an optical mask over a layer of PMMA material, exposing the PMMA material to x-rays, then developing using a photoresist process. The remaining PMMA material is then electroplated with metal. Once the metal has reached an appropriate thickness, it is detached to become a metal mold that is used in a microembossing procedure, in which the metal mold is pressed against a heated layer of plastic material. Once the mold is pressed down to its proper distance, the plastic material is cooled until solidified, and the mold is then detached, thereby leaving behind an array of microneedles.

Abstract: A component having a metallic foil surface secured to an injection moulded plastics material substrate is described together with a corresponding method of manufacture. The foil may be secured adhesively to the substrate either as an alternative or in addition to mechanical engagement. Where required, the foil may be pre-shaped to co conform substantially to an internal surface of an injection-moulding tool.

Abstract: A method of making a pultruded part having a uniform cross-section using a novel reinforcing mat. The method comprises orienting a plurality of longitudinal rovings along a longitudinal axis of a pultrusion die; providing a reinforcing structure comprising a permeable transport web of staple fibers attached to a plurality of first reinforcing fibers oriented so that the portion of the first reinforcing fibers oriented in a direction transverse to the longitudinal axis comprises at least 40% of a volume of materials comprising the reinforcing structure; shaping the reinforcing structure to generally conform with a profile of the pultrusion die; combining a resin matrix with the longitudinal rovings and the reinforcing structure in the pultrusion die so that the longitudinal rovings and the reinforcing structure are substantially surrounded by the resin matrix; at least partially curing the resin matrix in the pultrusion die; and pulling the pultruded part from the pultrusion die.

Abstract: An elastic breathable film is disclosed. The film is formed from a thermoplastic elastomer that contains a filler. Once the film is formed, the film is stretched causing the formation of micropores. The thermoplastic elastomer then undergoes phase separation between hard segment blocks and soft segment blocks which restores elasticity to the film. In one embodiment, the thermoplastic elastomer is a thermoplastic polyurethane elastomer.

Abstract: Microfibers and microfibrillated articles are prepared by imparting fluid energy to a surface of a highly oriented, highly crystalline, melt-processed polymeric film. The microfibers and microfibrillated articles are useful as tape backings, filters, thermal and acoustical insulation and as reinforcement fibers for polymers or cast building materials such as concrete.

Abstract: An economical method is disclosed for modifying the physical characteristics of a nonwoven fibrous web which involves passing the web between at least one pair of interengaged rolls to incrementally stretch the web, and then withdrawing the incrementally stretched web from between the rolls under tension. A web modified according to the disclosed method has advantageous elongation, extensibility and strength properties, as well as other desirable characteristics. In another aspect, a method is disclosed for forming a composite material by combining a modified nonwoven web with a polymeric film, or an elastic member, which may be liquid impervious yet breathable. In yet other aspect, a method is disclosed for forming a composite material by combining a modified web with a polymeric film which is rendered liquid-impervious yet breathable while the method is performed.

Abstract: In a method for making a permeable film, a physical force is applied to a film of a first material containing particles of a second material which is different from the first material. The second material has a higher susceptibility to the physical force than does the first material. Applying the physical force to the film affects the particles which in turn affect the first material of the film, thereby increasing permeability of the film.

Abstract: A method for forming a hollow bottom of an acrylic cup by forming a cup body by injecting a molding with a liquid transparent or semi-transparent acrylic material into a mold to form a mushroom shaped cavity. The cavity in the bottom of the cup body is filled with a gas, permitting the whole cup to appear to have a three dimensional (3D) visual effect. The cavity of the bottom of the cup can be filled with a non-colored or colored liquid to permit the whole cup to contain a deflected visual effect of a plurality of colored layers.

Abstract: A mold for a microlens includes a substrate at least a portion of which is electrically conductive, such as an electrically-conductive substrate or a substrate with an electrode layer, an insulating mask layer formed on the substrate and including an opening or plural openings, and a plated layer electroplated in the opening and on the mask layer. A first condition that a diameter or width (&phgr;) of the opening has a relation of &phgr;≦0.35R, wherein (R) is a radius of curvature of the plated layer right above the opening, or a second condition that the diameter or width (&phgr;) of the opening is &phgr;≦10 &mgr;m, is met.

Abstract: A method of manufacturing a part having at least one mechanically weakened area includes a step of producing a thermoplastics material part and at least one cycle of steps entailing forming a localized opening through an area of the part, heating the part locally by means of a heating probe so as to render the aforementioned area of the part plastic, and using a punch to modify the geometry of the area rendered plastic so as to delimit in the part a mechanically weakened area constituting a hole or hole precursor.

Abstract: A very lightweight tubular building element for the construction of reinforced concrete floors and roofs; providing the formwork for the casting in place of the structural concrete and a high quality finished ceiling at the same time. It is a single component that can be installed easily and efficiently without heavy equipment or special craftsmanship; afterward the component is not removed, but stays permanently integrated in the concrete floor or roof. It forms a deck that is impervious, eliminating cumbersome cleaning during construction and leakage afterward, saving the common need of a costly waterproofing membrane over the slab. The formwork deck, composed of a plurality of the invention component, weighs less than four (4) pounds per square foot; and a single component for a common 15 feet span weighs less than 30 pounds, which can be easily handled by only one laborer.