Abstract: A simplified lost-core molding system that combines otherwise redundant features such as platens and hydraulic cylinders ordinarily found in separate core molding stations and product molding stations. The preferred system locates the core mold and the product mold between the platens of an injection molding machine and applies a common clamping force to the core mold and to the product mold.

Abstract: This invention relates to a method of producing a lost mold for titanium casting from a curable embedding compound, which contains at least one oxidizable ingredient, in particular zirconium.

Abstract: An indirect solid free form scaffold manufacturing technique is provided. More particularly, the present invention provides a set of molds, casting methods, mold removals, and surface modification techniques that are compatible with image-based design methods and with solvent, melt, and slurry casting of polymers and ceramics.

Abstract: A lost core method for producing a hollow structure which method is characterized by fixing the lost core (11) which is to be used in the mold (12) with at least one insert (14), with the insert becoming part of the workpiece (10) to be produced. This is accomplished by casting the insert (14) in the hollow structure. In this way no openings for positioning the lost core (11), which subsequently would have to be closed with a cover, are created in the hollow structure (10) which is to be produced. The described process is therefore useful to advantageously influence the reliability of the resulting molded articles, as well as to favorably influence the manufacturing costs.

Abstract: This invention relates to microfabricated surgical devices made of a conformally coated polymer.

Abstract: This patent application describes the use of molecular imprinting as a means for preparation of anti-idiotypic imprint matrices. With this technique, imprints of artificial or natural molecules including their recognition sites, such as of molecularly imprinted polymers or biological receptors, antibodies or enzymes, can be prepared. In the former case, using the original imprints as casts or molds in a subsequent polymerisation step, utilising preferentially functionally complementary monomers, the formation of imprint materials containing recognition sites complementary in shape and functionality with the original imprint can be obtained but being of different composition. Alternatively, imprints or images of the artificial or biological species can be obtained directly. The so formed preparations can be used in a vast variety of applications, e.g. as new drugs, inhibitors or new affinity materials.

Abstract: A process is described for making gourd molds useful in the production of decorative ceramic and other articles which bear the textures of the gourd interior. Articles produced may also serve as models for use in the manufacture of production molds. Steps in making the gourd molds include selection, cutting, and removal of pulp; steps in using the gourd molds include treating with a release agent, casting, and removal of the gourd mold from the molded article.

Abstract: Bicycle frame components without laps made by a method comprising; shaping a fluid-removable core in the general form of the component, placing a flexible inflatable bladder around the core, wrapping over the assembly of core and bladder at least one ply of fiber impregnated with a curable resin, forming a cured part by inflating the bladder while the assembly of core, bladder, and impregnated fiber is in a mold to force the plies against the inner surfaces of the mold, such that compaction of the fiber against the mold is predominantly from the bladder inflation and not from the core, and heating to cure the resin to form a cured part, removing the bladder and the fluid-removable core from the interior of the cured part by disintegrating the fluid-removable core with a fluid sufficient to allow removal of the core and the bladder.

Abstract: A method of fabricating a removable mandrel for use in filament winding a container, includes the steps of providing and inflating an internal bladder. A dry 3-D fabric layer of a given thickness is layed-up about the inflated bladder. An external vacuum/pressure bag is installed about the dry fabric layer. The dry 3-D fabric layer is impregnated with a liquid soluble resin between the internal bladder and the external bag. The resin then is cured to rigidify the fabric layer to form a mandrel structure. The container then can be wound on the mandrel formed by the cured and rigidified fabric layer, and the resin can be subsequently washed out to remove the fabric layer.

Abstract: A method of creating a fluid meter housing is disclosed wherein molten material is injected into a cavity formed between a core and a mold. After cooling, the material assumes the shape of the housing and contains the core. Upon heating, the core melts and may be removed from the interior of the housing.

Abstract: A method for forming convexities and/or concavities on cloths for a garment at almost entire portions of the garment or any desired portion of the garment without any substantial limitation from a design point of view. The method for forming a garment having convexities and/or concavities which can expand and contract in both the weft and wrap directions like a knitted fabric. Cloths including thermoplastic fiber are cut into parts of the garment, the parts are sewn in a shape of the garment. The garment is overlaid on a thermo-shrinkable cloth. They are sewn together with stitches of water-soluble threads. The sewn cloths are heated under dry heat and without applying any pressure to the cloths so as to permit the thermo-shrinkable cloth to shrink and form convexities and/or concavities on the cloths of the garment. The water-soluble threads are solved and removed, and the cloths of the garment are separated from the thermo-shrinkable cloth.

Abstract: A sacrificial plastic mold having an electroplatable backing is provided. One embodiment consists of the infusion of a softened or molten thermoplastic through a porous metal substrate (sheet, screen, mesh or foam) and into the features of a microscale molding tool contacting the porous metal substrate. Upon demolding, the porous metal substrate will be embedded within the thermoplastic and will project a plastic structure with features determined by the mold tool. This plastic structure, in turn, provides a sacrificial plastic mold mechanically bonded to the porous metal substrate which provides a conducting support suitable for electroplating either contiguous or non-contiguous metal replicates. After electroplating and lapping, the sacrificial plastic can be dissolved to leave the desired metal structure bonded to the porous metal substrate. Optionally, the electroplated structures may be debonded from the porous substrate by selective dissolution of the porous substrate or a coating thereon.

Abstract: A ceramic investment shell mold is reinforced with a carbon based fibrous reinforcement having an extremely high tensile strength that increases as the mold temperature is increased especially within the range of casting temperatures employed for casting large directionally solidified industrial gas turbine components. The carbon based fibrous reinforcement is wrapped or otherwise positioned around the repeating ceramic slurry/stucco layers forming the intermediate thickness of the shell mold wall. The reinforced shell mold can be used to cast large directionally solidified industrial gas turbine components with accurate dimensional control.

Abstract: A manufacturing method comprising the steps of forming at first solidified wax layer of a desired shape, depositing onto the first solidified wax layer at least one layer of a liquid resin formulation, solidifying the layer of liquid resin formulation, depositing a second wax layer on to the combination of the first solidified wax layer and the layer of solidified resin formulation, solidifying the second wax layer, and separating the solidified resin formulation from first and second wax layers. Preferably, the resin formulation comprises at least one monofunctional water soluble vinyl or acrylic monomer in combination with a low molecular weight aliphatic polymer having acrylic or methacrylic acid functionality. The solidified wax and resin formulation layers can be machined as may be desired to form mold of a given shape comprising wax layers when the layer of formulation is separated from the wax layers.

Abstract: A method of shaping polymeric structures by coating a support structure with a bond-preventing agent to attain a particular shape and subsequently coating the shaped structure of the bond-preventing agent with a polymeric bonding composition is provided. Such shaped polymeric structures can have one or more cavities which can be fluid-filled or gel-filled. Also provided is a hand-actuating retention female urinary catheter having an inner tube and an outer overcoat layer encircling the tube with an elastomeric collar with a shroud. A cavity containing a fluid is interposed between the tube and the overcoat layer. The cavity includes a balloon portion and a reservoir portion. The shroud encircles the reservoir section to inhibit the ballooning of the reservoir section when the reservoir section is squeezed to force fluid from the reservoir portion to the balloon portion through the sleeve portion of the cavity. The overcoat layer and the collar with a shroud are made of soft resilient material.

Abstract: The invention relates to a process for the preparation of molecularly imprinted polymers useful for separation of enzymes, which comprises the steps of reacting a complex of enzyme and affinity monomer, a comonomer and a crosslinker, with a polymerization initiator and a polymerization accelerator at ambient temperature and pressure for a period ranging between 2 to 24 hrs, thereby obtaining a crosslinked polymer, crushing the cross linked polymer obtained to fine particles, adding a solvent and extracting imprinted enzyme from the polymer, obtaining the molecularly imprinted polymer, contacting the imprinted polymer with aqueous solution containing imprinted enzyme or a mixture of imprinted enzyme and other enzymes and isolating the enzyme-adsorbed polymer.

Abstract: A method of making molded parts employing Shape Deposition Manufacturing (SDM) techniques. First, SDM processes are used to make a layered structure having support segments and mold segments. The support segments are made of material which may be removed from the mold segments (e.g. dissolved or melted). The mold segments are made of a material which can function as a mold. The mold and support segments are sequentially deposited (e.g. in layers) and shaped (e.g. machined) to form a mold. The support segments define the shape of the part to be manufactured. The mold segments are removed from the support segments by dissolving or melting away the support segments, leaving an empty mold. Then, part material is cast into the empty mold. The mold is removed, providing a molded part. The part material can be a gelcasting slurry, for example. The present method provides homogeneous or heterogeneous parts having shapes which are accurately defined by the SDM process.

Abstract: The invention relates to a Resin Transfer Moulding (RTM) process for manufacturing fiber-reinforced components (31) with at least one closed or undercut space (35). A two-part mould with a cavity is charged with reinforcing fibers and a shape-stable supporting core of wax that can be melted out of the cavity. The core is produced from a cast preform by means of at least one shape-forming step. A plastic matrix capable of flowing is injected into the cavity of the closed mould forming a shaped fiber-composite mass and hardened to give the fiber-reinforced component (31). The shape-stable fiber-reinforced component (31) is removed from the mould and subjected to tempering. During tempering the core is melted and drained off from the fiber-reinforced component—leaving behind a closed or undercut space (35)—and the molten core material is cast to provide a new preform (1).

Abstract: A method of producing artificial fossil coral which is an artistic replica of a natural coral reef formed from a slurry of cement, sand, ground PVC chips, colorant and water admixed with artistic rigid lightweight sponge or Styrofoam. Fiber glass strands are used to provide a plant like look to the artificial fossil coral and coloring of the artificial fossil coral duplicates the colors found in natural coral reefs.

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: A core is made of a biodegradable material, reinforcing fibers and non-hardened resin are laminated on the core so as to form a fiber-reinforced composite material. Then, the fiber-reinforced composite material is hardened, and then biochemically active substances, such as microorganisms and enzymes, are brought into contact with the core so that the core is biochemically degraded and removed.

Abstract: The forming tool for making glass or plastic products has a cooling system and is made by a method including first determining shape and position of interior spaces for cooling ducts or cooling chambers (8) of the cooling system in the forming tool, according to required location-dependent cooling performance in the cooling system; providing a vacuum-tight sealed capsule (4) containing at least two materials (6,7) in which the interior spaces having the appropriate shape and position are formed by providing predetermined bounding surfaces (5) between the at least two materials, wherein one of the materials is a heat-resistant filling material (6) that is soluble in a liquid; subjecting the vacuum-tight sealed capsule to a hot-isostatic-pressing process to form a combined body within the capsule (4), in which the filling material (6) is incorporated; then working the combined body to form a required predetermined outer surface of the forming tool and removing the filling material (6) from the combined body to

Abstract: Bicycle frame components without laps made by a method comprising; shaping a fluid-removable core in the general form of the component, placing a flexible inflatable bladder around the core, wrapping over the assembly of core and bladder at least one ply of fiber impregnated with a curable resin, forming a cured part by inflating the bladder while the assembly of core, bladder, and impregnated fiber is in a mold to force the plies against the inner surfaces of the mold, such that compaction of the fiber against the mold is predominantly from the bladder inflation and not from the core, and heating to cure the resin to form a cured part, removing the bladder and the fluid-removable core from the interior of the cured part by disintegrating the fluid-removable core with a fluid sufficient to allow removal of the core and the bladder.

Abstract: A container for cross-linking composite materials on dental bridges and arches and on individual teeth, comprising: a plurality of plate-like elements which can be stacked and clamped together, at least one of the plate-like elements, which is internal to the plurality of plate-like elements, being constituted by a plurality of blocks which can be removed independently of each other to form an area which is suitable to constitute a mold into which it is possible to place a metallic structure on which the elements of a dental prosthesis are to be formed, the at least one of the plate-like elements and a plate-like element that is adjacent thereto in an upward region and constitutes the top plate-like element of the container being both made of a material which is transparent to light.

Abstract: Cores for manufacture of molded products are fabricated from ceramic microspheres in combination with 5-20% polymer binder in water solution, the binder comprising poly(2-ethyl-2-oxazoline) and polyvinylpyrrolidone.

Abstract: The invention concerns a process for producing a mold, wherein a hollow space is formed within a rigid mold frame (2) which corresponds to the shape of the component to be produced. According to the invention one fills the mold frame, with the exception of an area which surrounds and is in close proximity to the hollow space, with a plurality of filler elements (6), which are formed into at least an essentially incompressible shape. Subsequently, a model (8) of the component to be produced is introduced into the mold and the interstitial space between the model and the filler elements is filled with a masking material or mold shell forming material (4).

Abstract: The invention relates to a method and apparatus for the production of double-walled hollow sections by means of internal high-pressure forming, a first hollow section being inserted into a second hollow section, after which the double-walled hollow section thus formed is subjected to high internal fluid pressure in such a way in an internal high-pressure forming die that the double-walled hollow section is expanded. During this process, an air gap is formed between the first, inner, hollow section and the second, outer, hollow section.

Abstract: A method of shaping polymeric structures by coating a support structure with a bond-preventing agent to attain a particular shape and subsequently coating the shaped structure of the bond-preventing agent with a polymeric bonding composition is provided. Such shaped polymeric structures can have one or more cavities which can be fluid-filled or gel-filled. Also provided is a hand-actuating retention female urinary catheter having an inner tube and an outer overcoat layer encircling the tube with an elastomeric collar with a shroud. A cavity containing a fluid is interposed between the tube and the overcoat layer. The cavity includes a balloon portion and a reservoir portion. The shroud encircles the reservoir section to inhibit the ballooning of the reservoir section when the reservoir section is squeezed to force fluid from the reservoir portion to the balloon portion through the sleeve portion of the cavity. The overcoat layer and the collar with a shroud are made of soft resilient material.

Abstract: A method for forming removable dentures using injection molding techniques wherein a cyanoacrylate base material is applied to the sides of the denture teeth, an activator or accelerator compound being sprayed onto the deposited base material whereby the base material is rapidly cured. The denture is then placed in the lower half of a mold, or flask, and a plurality of sprues are positioned therein. The upper flask portion is then attached to the lower half and the assembled flask is then invested with plaster material. The activated gel enables the teeth to be retained in position in the lower half of the flask. The flask is then placed in hot or boiling water and then deflasked to remove the melted wax. The flask is then reassembled and polymer injected therein filling the areas previously occupied by the wax. After the polymer is cured, the prothesis is removed, polished and then returned to the dentist.

Abstract: A method for manufacturing a hollow component made of composite materials, in particular a hot-polymerizing resin/fiber composite. The component (1) comprises enclosing walls (3) which subtend at least one cavity (2).

Abstract: A method for producing a multiplicity of fastener element molding cavities extending from a mold surface, for molding a plastic product having fastener elements integrally molded with and extending from a product base, and a mold so produced. The mold cavities are formed by depositing multiple layers of plating material on a workpiece in a predetermined pattern selected to produce a desired mold cavity shape, or by depositing a thick stratum of plating material over an array of fastener elements and then removing the fastener elements to leave shaped cavities within the plating material. The mold may be in the form of a roll or belt for continuous processing, or in any form for discrete injection molding. Molds having fastener element cavities defined by rigid cast materials are also disclosed.

Abstract: The metal content of a thermoplastic composition containing an undesirably high concentration of metal can be reduced by adding to 100 parts by weight of the composition at least about 0.3 parts by weight of a chelating agent and sufficient water to chelate metal in the composition to form chelated metal in the composition, and then removing at least some of the chelated metal from the composition.

Abstract: A container for asphalt includes a sidewall and a bottom assembled to the sidewall to form the container for holding the asphalt in the container, the bottom thereafter being melted with the asphalt without adversely affecting the asphalt properties.

Abstract: Tool having a molding surface is formed from a flowable material (e.g., powder material) wherein the shape of molding surface is formed from a molding process using a master pattern having a surface with a shape substantially the same as the shape of the molding surface to be formed. The tool has at least one thermal control element located within it and spaced from the molding surface where a component used in forming the thermal control element is located within the flowable material prior to solidifying the material. The powder material is preferably a mixture of metals. The thermal control elements include fluid flow paths, heating elements, temperature sensors, and the like.

Abstract: A toroidal core is produced on a rim 1 comprising a central portion connecting two annular lateral anchoring zones. The rim has an air passage orifice which can be selectively closed or opened and connected to a source of pressure, to the atmosphere or to vacuum. A conduit 3 passes through the rim and has a valve 30 which can be selectively closed or opened, the conduit extending to an orifice to which a pipeline can be connected by a suitable flange 13. A stretchable membrane 2 is mounted on the radially outer side of the rim and is fastened to it in air-tight manner on anchoring zones over the entire periphery of said rim so as to define a closed space on the radially outer side of said rim between the rim and the membrane. A fluid 6 fills said closed space to overflowing, said membrane being pressed against a mold 5.

Abstract: A method of fabricating a resilient model of an article of manufacture, such as an earth-boring drill bit body or component thereof, including fabricating the resilient model of the article of manufacture by layered manufacturing techniques. The resilient model may then be employed to cast one or more molds from refractory material. The molds may be used to fabricate the modeled article of manufacture. The invention also includes a resilient, layer-manufactured model of an article of manufacture, such as an earth-boring drill bit.

Abstract: The present invention relates to a method for making a three-dimensional body, the construction of which is realised in layers by a purposeful application of material. According to the invention, two different materials are applied to each layer. One is purposeful applied in line along the outer edge of the three-dimensional object in the corresponding section plane, the remaining surfaces being filled with the second material.

Abstract: An improved process for slip casting molds that can be more economically automated and that also exhibits greater dimensional stability is disclosed. The process involves subjecting an investment pattern, preferably made from wax, to successive cycles of wet-dipping in a slurry of colloidal, silica-based binder and dry, powder-coating, or stuccoing, with plaster of Paris or calcium sulfate mixtures, to produce a multi-layer shell over the pattern. The invention as claimed entails applying a primary and a secondary coating to the investment pattern. At least two (2) wet-dipping On in a primary slurry and dry-stuccoing cycles provide the primary coating; and an additional two wet-dippings and dry-stuccoing cycles provide the secondary, or back-up, coating. The primary and secondary coatings produce a multi-layered shell pattern. The multi-layered shell pattern is placed in a furnace first to cure and harden, and then to vaporize the investment pattern, leaving a detailed, high precision shell mold.

Abstract: A method of diametrally expanding an elastic tube (6), which includes the steps of inserting a distal end portion of a expansion member (1) into an elastic tube (6), the expansion member (1) being provided at least at a surface thereof with a solidified layer of a low melting point material, and the distal end portion (4) of the expansion member (1) being tapered, a tip end of which having a diameter which is equal to or smaller than an inner diameter of the elastic tube (6), and moving the elastic tube (6) over the solidified layer to diametrally expand the elastic tube (6), the surface of the solidified layer being made into a low frictional surface due to a melting of the low melting point material.

Abstract: A method of manufacturing a golf club head that includes a peripheral shell constituted by an assembly of walls obtained by injecting a plastic material forming an inner cavity enclosing at least one inner insert kept immobilized by a partial plastic material coating of the shell. Prior to the injection step of the shell, an assembly is placed and immobilized in the mold which is comprised of a meltable core made of a second material having a melting point that is lower than the melting point of the plastic material in the space left free between the walls of the mold and the assembly, so as to coat the meltable core and all or a part of the free portion of the insert. Finally, all or a portion of the meltable core is eliminated to enable an inner volume to be freed so as to form the inner cavity.

Abstract: A method for molding high precision components is provided that allows inexpensive, rapid fabrication of components using a process involving a silicon substrate, in which the mold pattern is created using multiple mask layers, a deep reactive ion etch process and photolithographic patterning techniques.

Abstract: A method of making a ceramic casting mould contains forming a contact layer on a disposable wax-type pattern of the article to be cast, placing the pattern in a preparation mould for defining the outer shape of the casting mould and filling the cavity formed between the pattern and the preparation mould with a ceramic slip which expands to form a coherent cellular foam adhering to the surface of the pattern, removing the pattern and adhered foam from the preparation mould after from 5 to 30 minutes, eliminating the pattern to leave a casting mould formed by the contact layer and the adhered foam, and then firing the casting mould to strengthen said mould. Ceramic slip compositions are also described.

Abstract: A bypass conduit having a desired hollow internal geometry for defining a bounded blood flow path from an open first end positioned in a heart chamber and an open second end connected to a lumen of a coronary vessel is made by forming a master having an external surface with an external geometry complementary to the desired internal geometry of the conduit. The external surface of the master is coated with pyrolytic carbon to define a pyrolytic carbon conduit of pyrolytic carbon bonded to the external surface of the master and with the pyrolytic carbon having an internal surface with a conduit geometry complementary to the external geometry of the master. The master is removed from the pyrolytic carbon conduit.

Abstract: The invention comprises devices composed of at least one microscopic hollow tube having a wall of single or multiple layers with a thickness of at st one nanometer and a diameter of at least 5 nanometers. The walls of the tubes can be formed from a wide variety of materials, some of the preferred materials include metals, polymers, carbon, ceramics, glasses. If the space between the tubes is filled, the tubes become channels in a monolithic or composite body. The channels can have a random or ordered orientation. The interior of the tube walls can be coated with a desired material such as a catalyst and also may have depressions or elevations therein that were imparted to the fibers upon which the tubes are formed. The wall layers may be porous for the purpose of removing the fiber therethrough. Microtubes and microtube devices may be interfaced with the macroscopic world in a number of ways.

Abstract: A structure of solid material for use in making an investment casting mold and a method of making it are disclosed. The structure has a plurality of levels of spaced plates arranged such that in plan view the plates define a plurality of adjoining polygonal formations. The method includes solidifying portions of a body of liquid material to provide a first set of spaced plates, solidifying further portions at different levels to provide at least a second set of plates oriented transversely of plates of the first set. Adjacent sets are interconnected along side edges in essentially point connections.

Abstract: In a process for producing a profile by profile extrusion of a thermoplastic resin, a melt of the thermoplastic resin is extruded through a die to form the profile. The process is improved by utilizing a thermoplastic resin having a composition of from about 99.95 to about 98.0 weight percent amorphous or semicrystalline polyester and from about 0.05 to about 2.0 weight percent of a zinc salt of an organic acid. The improvement of the process is either by increasing speed or decreasing temperature of a profile extrusion process already operating at a maximum speed and/or temperature with experiencing melt fracture. When melt fracture is present in the profile extrusion process, a method for reducing melt fracture in a profile is accomplished by combining from about 99.95 to about 98.0 weight percent amorphous or semicrystalline polyester and from about 0.05 to about 2.

Abstract: A water soluble core comprising iggregate particles of an inert material and water soluble polyvinyl alcohol (PVA) binder results in an improved core composition having a longer shelf life and better release properties than other water soluble cores. The resultant core can be produced in less time and with less energy than other seater soluble cores, but is just as effectively remove d from the molded product upon exposure to water.

Abstract: A method for producing high performance components by the consolidation of powdered materials under conditions of hot isostatic pressure. The method uses the inclusion of reactive materials mixed into pressure-transmitting mold materials and into the powder to be consolidated to contribute to in-situ materials modification including purification, chemical transformation, and reinforcement. The method also uses encapsulation of the mold in a sealed container to retain the mold material in position, and to exclude air and contaminants.

Abstract: An electronic part having a complicated internal configuration is integrally molded without dividing the configuration into a plurality of sections, thereby reducing the cost and improving the quality of the electronic part.

Abstract: A flexible and resilient positive pattern is made for a desired high temperature metal or ceramic part such as a gas turbine impeller having a complex geometry with walls defining undercut spaces, and the pattern with flexible walls is dipped into a ceramic molding media capable of drying and hardening. The pattern is removed from the media to form a ceramic layer on the flexible pattern, and the layer is coated with sand and air dried to form a ceramic layer. The dipping, sanding and drying operations are repeated several times to form a multiple layer ceramic shell. The flexible wall pattern is removed from the shell, by partially collapsing with suction if necessary, to form a first ceramic shell mold with a negative cavity defining the part and to provide for reusing the pattern. A second ceramic shell mold is formed on the first shell mold to define the back of the part and a pour passage, and the combined shell molds are fired in a kiln.