Abstract: An electric power steering apparatus including a reduction mechanism 5 for transmitting an output of a steering assist motor 1 to a steering mechanism through a worm 3 and a worm wheel 4, in which the worm wheel 4 is formed by a thermosetting synthetic resin filled with a sheet 6 of aramid fibers having a low attacking property to a counter member and an effect of improving the abrasion resistance of the synthetic resin. Even when the reduction mechanism is used in an engine room or the temperature of the reduction mechanism is raised by frictional heat with heightening power, the reduction mechanism is durable, and further the gears have excellent abrasion resistance and toughness and improved durability.

Abstract: Solid rollers of a urethane material are formed in closed mold formed by a tube and two end plugs spaced by a shaft, the latter becoming the shaft for the roller. The closed mold avoids rough grinding to a cylindrical shape, as well as avoiding the resulting waste of material and introduction of defects that arise from rough grinding. The formation of bubbles during injection of the urethane material is avoided by filling the closed mold with carbon dioxide gas prior to injection. The formation of gate marks in the urethane material is avoided by repositioning the end caps after injection to separate the injection gate from the cylindrical cavity. The need to trim the ends of the roller is avoided by providing an annular cavity between the top end cap and the tube that receives excess urethane material to be drawn into the cylindrical cavity as the urethane shrinks during curing.

Abstract: A method of making a concrete item comprising the steps of: building a mold; preparing a concrete mixture; pouring the concrete mixture into the mold; removing the concrete item from the mold; and chiseling the concrete item with a pneumatic chisel.

Abstract: A method of manufacturing a composite uses a hybrid tool which serves both as a form on which constituent materials are applied for bonding or curing into a part in a desired configuration, and as a fixture for holding the bonded or cured materials in the originally applied position during subsequent machining of a peripheral edge of the part. The method includes fabricating a face sheet of composite material having a facing surface configured to the reverse of a desired shape of one surface of a part to be made on the tool. The materials for the part are applied on the face sheet, debulked, bonded or cured, and edge trimmed thereon, all while on the face sheet in the originally applied position.

Abstract: Method for producing a power drive belt having drive teeth on both sides of the belt. The teeth include abrasion resistant facing fabric on both sides of the belt. The power drive teeth are molded on both sides of the belt slab in a planar mold having power teeth-forming recesses in first and second mold halves. In a preferred method, a portion of the belt is transfer molded by pressing tooth stock material through the cord layer and another portion of the belt is compression molded. The mold is provided with edge channels and/or waste pockets to accommodate excess tooth forming material generated during the molding process.

Abstract: Floor coverings and methods of producing same, are provided. A vehicle floor covering includes a barrier layer of polymeric material and a sound-absorbing backing layer bonded to the barrier layer. The barrier layer exposed surface includes various aesthetic and/or functional features. The barrier layer has variable thickness.

Abstract: The invention relates to a method of producing a dental prosthesis, comprising the steps:

Abstract: A surface micromachining process for a resin mold including a layer of a resin as a material of the resin mold, which layer has a product's surface forming plane, and a back surface reinforcing member for reinforcing the resin layer. The product's surface forming plane is micromachined by means of at least two masking/blasting treatments. The treatments comprise a primary blasting step of sticking a first mask sheet having a specific window on the product's surface forming plane and blasting blast particles to the product's surface forming plane via the first mask sheet, and a secondary blasting step of peeling the first mask sheet, sticking a second mask sheet different from the first mask sheet on the product's surface forming plane, and blasting blast particles to the product's surface forming plane via the second mask sheet.

Abstract: The present invention relates to a method for producing a part (108, 200, 300), comprising the following steps:

Abstract: A concrete block produced from a workpiece that includes at least a portion of a top surface that is roughened by a roughening assembly. The roughening assembly may include a shaft having a plurality of roughening members, the shaft being rotated in a direction opposed to the movement of the workpiece. A splitting mechanism is provided downstream of the roughening assembly to split the workpiece into one or more blocks. The blocks may be placed in a wall having a setback, with the roughened top surface of each block enhancing a natural appearance of the ledge created as a result of the setback.

Abstract: A process for making a heat treated ground ceramic cutting tool and the resultant cutting tool. The process includes the steps of: providing an uncoated ground ceramic cutting tool having at least a portion thereof ground; and heat treating the uncoated ground ceramic cutting tool so as to form the heat treated ground ceramic cutting tool.

Abstract: In a method of manufacturing a friction member used for a vibration wave driving apparatus including a vibration member, a contact member which is brought into frictional contact with the vibration member and relatively moved by vibrations produced in the vibration member, and the friction member formed on one of friction portions of the vibration member and contact member, a molded member is formed by compression molding of a fluoroplastic powder and an additive, a sintered member is formed by sintering the molded member, a sheet is formed by cutting the sintered member in the form of a sheet, and a modified layer formed by cutting is removed from the friction surface of the sheet.

Abstract: Various methods and apparatus for simultaneously texturing two single-sided hard memory disks is provided. The two disks are placed in a concentric contact merge orientation such that the outwardly facing surface of each disk may be simultaneously subjected to texturing by equipment designed to texture one double-sided disk.

Abstract: The present invention relates to a method for improving the abrasion resistance of a spun-bonded nonwoven without substantially adversely affecting its hand or drape characteristics, by incorporating low melt binder fibers into the web during the laydown phase of the spun-bonded nonwoven production process. More specifically, improved abrasion resistance is achieved by intimately blending continuous binder fibers with the primary extruded fibers in a spun-bonded nonwoven web. Also encompassed within this invention is a spun-bonded nonwoven fabric having improved abrasion resistance and comprised of primary extruded fiber and low melt binder fiber such that the binder fiber comprises between about 1 and about 50 weight percent on weight of the spun-bonded nonwoven fabric.

Abstract: A mouse pad fabrication method utilizing bark sourced from the cork tree. After the purging and cleaning of surface foreign matter, the tree bark is pulverized into appropriately minute particles. These are then blended with a natural resin glue and after becoming mixed evenly, the mixture is press formed under high temperature and high pressure and then trimmed to a required thickness. High temperature water misting is utilized for the rough edge removal task to soften and flatten the rough edges. As such, the finished mouse pad so fabricated has a more perfect, planar surface and provides for comfortable, non-injurious user contact. Since the finished product is constructed of cork, countless minute air holes are present in its corpus and junctions, which not only traps debris, but prolongs the usable service life of a mouse and, furthermore, enables smooth mouse operation during utilization.

Abstract: A mold for a golf ball comprises an upper portion (1) and a lower portion (3). A large number of projections (7) for dimple formation are provided on a cavity surface (5) of each of the upper portion (1) and the lower portion (3). A parting surface (8) of the upper portion (1) and the lower portion (3) has a concavo-convex shape. The parting surface (8) includes a first horizontal plane (13), a second horizontal plane (15) and an inclined surface (17). Circumferential central angles &phgr; of the first horizontal plane (13) and the second horizontal plane (15) are 55 degrees or less. A total value &Sgr;&phgr; of the circumferential central angles &phgr; is 30 degrees to 330 degrees. An inclination angle &agr; of the inclined surface (17) to a horizontal direction is 10 degrees to 60 degrees. A central angle &thgr; between the horizontal planes (13) and (15) and an equator (E) is 1 degree to 8 degrees.

Abstract: Apparatus for charging a substrate, comprising: an elongated charging member having a crowned surface; an elongated pressure member having, the pressure member being supported for pressure engagement with the charging member to form a nip therebetween adapted to receive the substrate. There is also disclose a method for making the apparatus.

Abstract: A process for the production of a manufactured article for coatings, for components of sanitary ware, kitchen fittings, etc., in polymerized transparent resin in which marble and other stones are embedded. The surface of the product is worked by brushing with abrasives, so as to obtain depressions corresponding to the resin, and slight projections with substantially uniform distribution corresponding to the inserts; advantageously, the inserts are “decapitated” to give smoothed surfaces.

Abstract: Solid rollers of a urethane material are formed in closed mold formed by a tube and two end plugs spaced by a shaft, the latter becoming the shaft for the roller. The closed mold avoids rough grinding to a cylindrical shape, as well as avoiding the resulting waste of material and introduction of defects that arise from rough grinding. The formation of bubbles during injection of the urethane material is avoided by filling the closed mold with carbon dioxide gas prior to injection. The formation of gate marks in the urethane material is avoided by repositioning the end caps after injection to separate the injection gate from the cylindrical cavity. The need to trim the ends of the roller is avoided by providing an annular cavity between the top end cap and the tube that receives excess urethane material to be drawn into the cylindrical cavity as the urethane shrinks during curing.

Abstract: This invention relates to windshield wiper system and method which utilizes a flexible member to account for compression loads in excess of a predetermined load, such as 30 percent, greater than a maximum load for the flexible member. The system utilizes a flexible pultruded composite material having a relatively low modulus of elasticity, yet relatively high elongation characteristics. The flexible arm bends to facilitate preventing damage to components in the wiper system when a compressive load applied to the flexible member is in excess of the predetermined load.

Abstract: The invention relates to a seamless model free of bond lines and to a method of making same. The method includes the sequential steps of providing a substructure having an exposed outer surface, applying a modeling paste to the outer surface of the substructure in the form of a continuous layer, curing the continuous layer of applied modeling paste, and machining said cured layer of modeling paste to the desired contour. The modeling paste of the invention is a mechanically frothed syntactic foam prepared by injecting inert gas with mechanical stirring into either a formed froth-forming composition, which is preferably a polyurethane or epoxy froth-forming composition containing microballoons.

Abstract: Extruded sections of synthetic fibers extruded from a side face of each rib in a V-ribbed belt are plastically deformed in the shape of sectors gradually broadened toward their distal ends. The extruded sections of the synthetic fibers are not heated beyond their melting point during a grinding process so as to be kept unmelted. The extruded sections of the synthetic fibers are raised from the side face of the rib so that microscopic unevenness is formed over the side face of the rib. The synthetic fiber is formed of nylon with a filament diameter of 20 &mgr;m or more.

Abstract: A unitary polymer substrate having a plurality of microfibers projecting from a surface is provided. The presence of the microfibers greatly increases the surface area and can impart a cloth-like feel to the surface. The projecting microfibers may have a variety of forms, including frayed-end microfibers, tapered microfibers, microfibers having an expanded cross-sectional shape, and microfibers having a very high aspect ratio. A number of methods of producing unitary polymer structures with a plurality of projecting microfibers are also provided.

Abstract: A method of forming a composite door is disclosed. The method comprises: mixing together a thermoplastic polymer with an organic fibrous material in a ratio such that the organic fibrous material constitutes 40 to 60 percent by weight of the mixture; extruding the mixture under heat and pressure to create a thin sheet form; cutting the sheet to a predetermined size; removing material from at least one surface of the sheet to create a homogeneous appearance devoid of obvious fibrous particles; thermoforming the sheet to impart to the at least one surface an exterior three dimensional door surface to create a thin door facing; and assembling two of the thermoformed thin door facings, a peripheral frame and a core material into a door.

Abstract: A method of preparing a smooth watertight concrete in-ground pool surface that eliminates the use of a plaster outer surface layer that includes allowing the concrete pool body to cure for at least thirty days at which time a grinder is used to grind the surface to a smoothness and depth that is watertight and that exposes aggregates within the pool surface resulting in an aesthetically desirable permanently finished pool surface.

Abstract: A part employing internally molded shapes and surface finish to provide cosmetic features or design elements includes a body, at least a portion of which is molded of a transparent or semi-transparent material having an internal surface and an external surface. A cosmetic feature is formed in the internal surface of the body and is visible through the body of the part from the external surface. In some embodiments, the part is within a mobile phone.

Abstract: An apparatus and a method for treating the surfaces and edges of a block to mimic the appearance of natural stone. The apparatus and method can treat up to four sides of a block, can be adjusted to provide varying degrees of surface and edge treatment, and useful in high volume block production equipment. Blocks are produced having a natural, weathered appearance without the damage, breakage, dust, or expense associated with conventional splitting and tumbling methods.

Abstract: In a method of manufacturing a friction member used for a vibration wave driving apparatus including a vibration member, a contact member which is brought into frictional contact with the vibration member and relatively moved by vibrations produced in the vibration member, and the friction member formed on one of friction portions of the vibration member and contact member, a molded member is formed by compression molding of a plastic powder and an additive, a sintered member is formed by sintering the molded member, a sheet is formed by cutting the sintered member in the form of a sheet, and a modified layer formed by cutting is removed from the friction surface of the sheet.

Abstract: A method for making freeform-fabricated core composite articles using freeform-fabricated machine. The articles are capable of being utilized as end products rather than prototype models by creating a core having an interior structure to provide strength to the core and to enhance the strength to weight ratio of the article.

Abstract: A method of making a prototype golf club grip includes the steps of providing a two-piece mold having a main chamber and a pair of blind bores extending from opposed ends of the main chamber, providing a mandril having an intermediate section and opposite ends, placing the mandril in the two-piece mold with its intermediate section in the main chamber thereof and its opposite ends in the blind bores of the two-piece mold, pouring polymeric material such as epoxy into the main chamber of the two-piece mold, curing the polymeric material to form a grip blank on the intermediate section of the mandril, removing the mandril and the grip blank from the two-piece mold, and machining the grip blank to form a desired shape and features thereon to complete the prototype golf club grip.

Abstract: The invention permits a boundary between a grained surface and a smooth surface to be seen clearly in a resin molded product, and facilitates manufacture and grinding of a mold for molding a resin. In an implementation, a resin molded product has a smooth surface adjacent to a grained surface on which microscopic asperities are formed. A step surface protruding toward the grained surface is formed on a boundary between the grained surface and the smooth surface.

Abstract: Apparatus and methods are disclosed for making masonry blocks with one or more surfaces having a roughened texture resembling that of a split block or natural stone. In one embodiment, a mold comprises a plurality of walls defining at least one mold cavity adapted to receive block-forming material. The mold defines an opening through which a formed, uncured block may be removed from the mold. At least one wall of the mold has a plurality of projections extending into the mold cavity so as to contact an adjacent surface of the uncured block in the mold cavity. The projections are positioned such that when the uncured block is removed from the mold, the projections texture the adjacent surface of the uncured block.

Abstract: Disclosed is a method to simplify the handling of micro-components (1, 18), wherein a micro-component (1, 18) is initially produced on a micro-component base plate (2). At least the open side surfaces of the micro-component (1, 18) are then cast using a hardening moulding material (4) whereupon the base plate (2) and/or the moulding material (4) covering the micro-component (1, 18) is removed. The magazine (5) for at least one micro-component (1, 18) comprises of a disk-shaped plate (5a) encompassing the micro-component (1,18) at least one its side surfaces (1c) is positive fit. The assembly method for micro-components (1, 18) includes a magazine (5) which is configured in the form of a disk-shaped plate containing at least one micro-component (1, 18) which encompasses at least on one of its sides in positive fit.

Abstract: The invention relates to a method for fabricating a decorative laminate panel, wherein the decorative laminate panel includes a decorative laminate layer and a core. The method is achieved by forming a decorative laminate of a predetermined size, placing the decorative laminate within a die cavity, injection molding the core within the die cavity while the decorative laminate remains within the die cavity to form a decorative laminate panel and releasing the formed decorative laminate panel from the die cavity. The invention further relates to a decorative laminate panel manufactured in accordance with the method defined above and a unitary edge profile member adapted for use in the fabrication of a compound injection molded decorative laminate panel.

Abstract: A unitary polymer substrate having a plurality of microfibers projecting from a surface is provided. The presence of the microfibers greatly increases the surface area and can impart a cloth-like feel to the surface. The projecting microfibers may have a variety of forms, including frayed-end microfibers, tapered microfibers, microfibers having an expanded cross-sectional shape, and microfibers having a very high aspect ratio. A number of methods of producing unitary polymer structures with a plurality of projecting microfibers are also provided.

Abstract: In a method of making an electrically conductive electrode member, a compound material, containing a binder made of polymer plastic and 80 weight % of a powdery electrically conductive material as filler, is introduced into a plasticizing screw of an injection molding machine for transforming the compound material to a plasticized material and discharging the plasticized material via a nozzle having a length of less than 15 mm for subsequent injection molding. The injection molding machine is constructed throughout a material flow passage from a point of introduction of the compound material to the injection mold to have only tapered portions which narrow a flow cross section by not more than 10:1.

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: A method is provided for making ligneous material boards into an endless board strand with a continuously operating press. The press includes two flexible endless steel belts which take the press material between them and carry it through the press. The steel belts thrust with friction-reducing elements against heated press plates of the press table and press ram and a cooling system that follows. The cooling system is configured as a double-belt holding apparatus with an applicable holding pressure up to a maximum of 0 to 0.05 N/mm2. A diagonal sawing apparatus, which is disposed directly behind the continuously operating press and ahead of the cooling system, divides the board strand into single boards. Several rows of coolant spray nozzles disposed on the backs of the holding belts making contact with the single boards.

Abstract: A method for forming a plurality of composite parts via resin transfer molding in a single molding cycle. The method includes the steps of using a mold having first and second mold members that cooperate to house a plurality of shims and placing a plurality of preform workpieces into the mold cavity such that at least one of the shims is disposed between each of an adjacent pair of the preform workpieces. A liquid resin is then injected into the mold cavity and subsequently cured to thereby form a cured workpiece matrix that is composed of a plurality of semi-finished composite parts and at least one shim separating the plurality of semi-finished composite parts from one another.

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 method and apparatus for the production of a workpiece of exact geometry and high surface quality, such as, for example, a forming tool, are disclosed. Preferably computer-controlled, the apparatus follows the method of the invention to produce the workpiece by radiation and compacting of nx successive layers of powdered starting material, each subsequent layer being formed on the uppermost surface of the previously formed layer. Following the radiation and compacting of each layer, at least one of the vertical lateral faces of the layer and of one or more underlying layers, all of which are surrounded by excess powdered starting material throughout the process, are mechanically finished, for example by a hobbing process or a peripheral grinding process.

Abstract: A method of forming ablative insulation coatings on aerospace structures and articles produced thereby. The method includes forming a mold having a cavity configured to complementarily receive at least a portion of the structure and directly molding the ablative coating to a surface of the structure by introducing a prepared ablative mixture, such as an epoxy resin, into the mold. The process may desirably include curing at atmospheric pressures to reduce the expense and equipment required in carrying out the process. The method of applying the ablative coating further includes features such as varying the thickness of the ablative coating from one portion of the component to another. Control of the thickness may be effected through use of spacers embedded into the ablative coating an formed of the same or similar material previously cured prior to placement in the mold.

Abstract: Disclosed is a method to simplify the handling of micro-components, wherein a micro-component is initially produced on a micro-component base plate. At least the open side surfaces of the micro-component are then cast using a hardening moulding material whereupon the base plate and/or the moulding material covering the micro-component is removed. The magazine for at least one micro-component comprises of a disk-shaped plate encompassing the micro-component at least one its lateral surfaces is positive joint. The assembly method for micro-components includes a magazine which is configured in the form of a disk-shaped plate containing at least one micro-component which encompasses at least on one of its sides in positive fit. Said magazine is held and maintained by a retaining device, whereupon the micro-component which is to be assembled is squeezed out of the magazine and simultaneously positioned in a specific location.

Abstract: A method and apparatus for forming a skid-resistant surface on a thermoformed object such as a bed liner. The method includes forming a blank of extruded plastic material, abrading the surface with a wire brush, reheating the blank and thermoforming the blank to open the abraded surface of the blank. The apparatus includes an extruder delivery mechanism delivering a blank of sheet material to a wire brush which is turned by an electric motor at a speed slightly greater and in the same direction as the travel of the blank under the roller.

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: In a method for producing a monofilament with reduced secondary binding forces of at least two commonly extruded polymers for the production of bristles or interdental cleaners which are slittable substantially axially through the action of mechanical forces, the at least two polymers of the monofilament are disposed in a regular geometrical arrangement with substantially axially extending boundary layers in which the reduced secondary binding forces prevail for generation of defined slits of flags.

Abstract: A molded display form (i.e. a mannequin) or other article is provided, made of an elastomeric material having a pigment and/or dye mixed therein, said form having a selected uniform color throughout the thickness of said material. Any desirable color may be selected, e.g., skin color (to approximate that of any race) grey, tan, red, blue, yellow, metallic colors such as gold and silver, and mixtures thereof. White and black molded articles are also provided herein. The processes of this invention are especially suitable for producing articles having a uniform color throughout without streaking. The forms of this invention are non-brittle, resist burning, and stand up well to high temperatures. If they are scraped or chipped, the uniform color of the material throughout will make the injury less noticeable. The material is also soft enough that seam lines may eliminated by buffing with synthetic pads, and because of the uniform color of the material, there is no need to paint over the buffed surface.

Abstract: Changing the contour of a recess (12) in a body of solid material to a revised contour wherein a pattern (24) is made having the revised contour and this pattern is placed in the recess with a curable plastic material (31). After the curable plastic material is hardened, the pattern is removed providing the revised contour (30) of the recess. The body of solid material can be a flow channel block.

Abstract: An improved structural reinforcement system for ceramic composite parts fabricated with polymeric ceramic precursor resins includes a mechanically interlocked mat of carbon or graphite filaments with a semi-random orientation. The carbon or graphite mat has a density of at least about 15% filaments by volume. Using graphite mat yields finished ceramic components that exhibit substantial ductility without the use of interfacial coatings, as well as good structural strength and even distribution of thermal energy.

Abstract: A method of making terrazzo floors with design inlays. The method utilizes pre-molded inserts as inlays in the finished floor, and generally includes four steps. First, inserts are pre-molded, which has design elements in terms of their color, nature of inclusions (chips, glass fragments, etc. and their colors), shape and/or a pattern of grooves in their upper surfaces. Second, the pre-molded inserts are placed on and affixed to the sub-flooring in a predetermined arrangement. Third, epoxy flooring mixture is poured to a height that fills the grooves in the inserts' upper surfaces and preferably cover the inserts. Fourth, the floor, after cured and hardened, is ground and polished to expose the upper surfaces of the inserts, which now become seamlessly integrated inlays within the overall finished floor.