Abstract: A racket frame is made by molding a thermosetting resin composition together with reinforcing fibers. Molds are made of flexible strip members, such as plastics, wood pulp, paper pulp, wood, bamboo, etc., which are bent to form a racket frame in a fitting, thereby reducing the production cost incurred in fabrication of expensive molds. The formed racket frame has no shell and core structure.

Abstract: A lens barrel assembly consisting essentially of a first and second barrel member having helicoid screw threads therebetween which enable said barrel members to be moved axially upon relative rotation therebetween is formed in a molding process wherein one of said barrel members is utilized as a mold element in the formation of the other barrel member with the other barrel member being formed by injection molding of resin material injected into a cavity defined at least in part by the first barrel member. The lens barrel assembly is formed with the barrel members in operative juxtaposition when they are removed from the mold cavity.

Abstract: A substantially entirely plastic rotary drum filter is made by applying a layer of plastic to the interior surface of a cylindrical mold, removing the mold, and applying at least one additional layer of plastic to the exposed exterior surface of the shell formed by the first layer. A plastic annular axial valve housing with plural valve chambers and a central valve receiving space is mounted to a head assembly at the head end of the shell. A tail assembly closes the opposite end of the shell to form the drum. Circumferentially spaced interior plastic bucket sections are positioned midway between the head and tail assemblies. Upon the periodic application of a vacuum to the valve chambers, filtrate is delivered from the exterior of the drum through an associated bucket and plastic drainage conduit to an associated valve chamber. Plastic reinforcing rings strengthen the drum along its length and in the region of the bucket section.

Abstract: Identical half-section shells of microscopic size, such as hemispherical shells from which spherical laser fusion targets can be made are capable of mass production by micro fabrication molding techniques. A body (preferably a hollow glass microsphere which is called a glass microballoon) provides a pattern for the hemispherical shells, and is used to produce an original mold section. One or more master molds are formed from this original mold section by replication. Many identical replica molds are made by casting soluble material onto the master mold and removing them therefrom. The replica molds are coated with one or more layers which will form the hemispherical shell wall. The material coating the flat background around the hemispherical cavity is referred to as the flange and is removed to form free standing shells. In order to remove the flange material, the coated replica molds are overcoated with a soluble material which is etched away to the level of the flange.

Abstract: Method for making a coded, resilient ear plug including forming an impression with wax and release agent, investing the impression, agitating to remove air, hardening the investment and after removal of the impression material casting a hardenable material in the investment cavity.

Abstract: A process for making a porous sintered body of calcium phosphate having continuous and fine pores distributed uniformly throughout the porous body is provided which comprises the steps of: preparing a slurry of amorphous calcium phosphate having a molar ratio of calcium to phosphor ranging within 1.59 to 1.80; adding a foaming agent to said slurry; dipping a porous body of an organic material having continuous and fine void channels into said slurry prior to or after foaming said slurry to allow said slurry to adhere on the internal walls of said void channels; heating said porous body of said organic material at a temperature high enough for decomposing said organic material to varnish into smoke and concurrently for thermally converting said amorphous calcium phosphate into hydroxyapatite to form a network of hydroxyapatite; and sintering said network of hydroxyapatite to form said porous sintered body.

Abstract: Flexible ceramic/organic webs are prepared by coating, using fixed nip techniques, a highly viscous, thixotropic material over at least two sides of an organic, thermoplastic substrate. The substrate, having fibers randomly arranged, highly dispersed and bonded at the filament junction, is the type which disintegrates at highly elevated temperatures. The resulting material is highly loaded with ceramic particles such that greater than 70 percent of the total weight of said web is ceramic material. Webs prepared in accordance with the present invention can be shaped into a variety of desired configurations and then fired at highly elevated temperatures causing the substrate to disintegrate, to thereby form ceramic articles having very high ceramic bonding properties.

Abstract: A method of making a games racket frame by injecting thermoplastics material into the space (13) between a fusible core (14) and a mould at a temperature above the melting point of the core. The core (14) is shaped to have locating lugs (15) to abut against the internal walls of the mould and hold the core in the desired position. The moulding is allowed to set and the core then melted out by raising the temperature sufficiently for that purpose but insufficiently to deform the moulding. The lugs (15) enable the core (14) to be located in the desired position in the mould and to resist displacement from that location during injection. The holes formed in the wall of the frame because of the abutment of lugs and mould wall can conveniently be utilized as stringing holes.

Abstract: A resin-coated sand comprising:(a) particles of sand coated with from about 1% to about 8%, by weight of the sand, of a novolak resin consisting essentially of about 50% to about 98% of a phenol-formaldehyde novolak resin and about 2% to about 50% of a catechol-formaldehyde novolak resin; and,(b) a curing agent.The sands are especially useful for forming foundry cores and molds.

Abstract: A method is provided for making shaped self-supporting carbon-fiber structure by initially forming a fluid mixture of curable binder and carbon-fiber. The mixture is poured into a mold, and a vacuum is applied to the mold to effect the separation of excess binder. Cure is effected of the residual binder to produce a removable self-supporting shaped carbon-fiber structure.

Abstract: The present invention presents a novel method for injection molding a header to the open-ended tubes of an elastomeric solar collector. Special mold pieces and mandrels are required to carry out the invention.

Abstract: This invention relates to the method of producing a flexible, life-like model of physiological organs. These models are produced by injecting under pressure for a predetermined time a settable material such as silicone. The organ is then digested in a solution leaving a solid fabricated model. A multi-layered mold is fabricated around the solid model and once formed, is disassembled to remove said model. The mold is then reassembled and after proper coating is filled with liquid wax or similar material which is permitted to solidify. The mold is again disassembled and the wax model removed. The surface of the wax model can then be polished and otherwise cleaned prior to dipping in a settable liquid such as silicone which allows a build-up coating to be applied to such wax model. The thus coated model is then placed in boiling water or other environment to melt out the core to form a hollow casting by the lost wax technique.

Abstract: Organ prostheses are manufactured starting from a support preformed in the shape of the prosthesis to be formed on which a sol giving on cooling a gel enabling a surface state approximating to that of a liquid-air interface is deposited, a hardenable flexible material compatible with body tissues is deposited thereon and the prosthesis removed from the mould. Ureter, bladder, vascular and cardiac prostheses made by this method are disclosed.

Abstract: An element having a molding surface defining the cavity of a mold for molding thermoplastic resin and a method of making the element. To regulate the cooling speed of the molten resin to be injected or placed into the cavity, the molding surface is provided by a thin metal layer and a layer of heat insulating material is formed on the inner side of the metal layer.

Abstract: A method of casting metal so that the finished casting will hold a precise dimension in certain critical areas in order to enable the finished casting to be used as a frame for objects such as coins and medallions which are die struck to precise dimensions. Means of and apparatus for rigidly maintaining the object inside the cast frame by inexpensive means which will not damage the object and which will allow the object to be easily removed from the frame if necessary.

Abstract: An organic solvent soluble resin and insoluble resin, and a ceramic powder or a metallic powder, if desired, a plasticizer and a desired additive are blended and molded and a molded product is treated with an organic solvent to dissolve the soluble resin, the plasticizer etc. and then, the treated product is fired to obtain a molded ceramic or metal having no cracking nor deformation and having high density.

Abstract: A method is disclosed for the preparation of implants, especially dental implants, from ceramic substances having in particular a porous surface which stimulates ingrowth of bone tissue.

Abstract: A method of making a composite structure upon a solid former having a low melting point, comprises placing the former together with the laid-up composite within a mould, raising the temperature of the mould such as to melt the former and expand it such that it consolidates the composite within the mould.

Abstract: A method of producing decorative cellular ceramic building materials in a single firing process from SiO.sub.2 -containing starting materials is disclosed according to which method at least the bottom of a refractory mold is covered with a first layer of a glass material or a glass forming composition which does not expand when heated and which has a melting point of 800.degree.-1200.degree. C., whereafter the SiO.sub.2 -containing starting material used for producing the cellular ceramic is applied in the form of a second layer on the first layer in the mold, whereafter the mold and its contents are heated to 800.degree.-1000.degree. C. for a period of time of such duration that the ceramic starting material and the glass material sinter together and the ceramic starting material obtains a porous structure.

Abstract: A method of making a panel for installation in the high velocity air flow region of an engine nacelle and other applications requiring sound absorbing material and increased air frame strength. The panel utilizes a single layer of either a metallic or nonmetallic cellular core with a solid or perforated septum disposed internally therein. The septum may have a planar or nonplanar configuration within the individual cells of the core thereby providing means for reducing the noise level of various sound frequencies created by a jet engine or any other sound producing devices for that matter. The planar or nonplanar septum provides structural stabilization and/or vibration dampening to a bonded sandwich assembly. The panel may also be used in strengthening air frame construction and other applications besides sound attenuating panels.

Abstract: Composite electron microscope grids for support of specimens and suitable for energy dispersive X-ray analysis are fabricated from an etched surfaced mold which is sacrificed after the grid casting. Preferably, the mold is made from a material with a different solubility or chemical resistance than the composite material forming the grid so that the mold can simply be dissolved after use. The mold itself is preferably etched using a photoresistive process for precisely etching the desired grid structure into the mold material. The mold process for making the grid can be utilized for molding other types of micro-components.

Abstract: A method for manufacturing work pieces such as fan blades, complete fan rotors and other bodies wherein a core is wrapped around with reinforcing means and the wound core is inserted in a mould, then liquid synthetic resin mixture is filled into the hollow space of the mould, and whereby after the synthetic resin hardens, the fan blades are removed from the mould.

Abstract: A molding process for forming a three-dimensional article in layers. In one embodiment, a matrix comprising a planar grid-like member having a plurality of openings formed therethrough is employed. In an initial layer, casting material and mold material are deposited in selected openings to form a portion of the article in that layer with the casting material surrounded by the mold material. The matrix is located sequentially in adjacent layers and in each layer, the selective deposition of casting and mold material is repeated whereby the article is formed layer by layer from the casting material held in place by the mold material. The casting material is solidified and the mold material is removed.In another embodiment, planar layers of material are sequentially deposited. In each layer, prior to the deposition of the next layer, a portion of its area is solidified to define that portion of the article in that layer.

Abstract: A method of manufacturing a ball for use in volleyball or soccer includes the steps of manufacturing a spherical hollow body of a brittle material, sticking cloth strips in an overlapping manner on the spherical hollow body to provide a bag body, cutting a predetermined portion of the bag body to make an opening thereon, collapsing the spherical hollow body in the bag body into pieces, taking the collapsed pieces out of the bag body through the opening, putting a tube having a valve through the opening into the bag body, sticking rubber ribbons on places corresponding to the overlapping portions of the cloth strips, and sticking leather sheets on the rubber ribboned bag body to provide an outer layer for the ball.

Abstract: A three-dimensional network porous metallic structure is formed by filling the internal cavity of a mold, which has been prepared by making use of a three-dimensional network resin pattern, through driving the molten metal into the cavity by a pressure or through sucking the molten metal into the cavity by reducing the pressure in the cavity. The porous metallic structure thus obtained is characterized by a large specific surface area, as well as a reduced pressure drop of fluid passing through this structure, and, therefore, is fit for various uses such as the material of fins of heat exchangers, various filters and so forth.

Abstract: Three-dimensional structures providing a plurality of separate interpenetrating, three-dimensional domains or channels or flowpaths, each of said domains or channels or flowpaths being a closed system of connected porosity or permeability and each of said domains or channels or flowpaths being interpenetrating within said structure, have been prepared. These structures are prepared from porous permeable precursor materials having a single three-dimensional domain or channel or flowpath as described above. Suitable precursor materials are provided by the abundant porous carbonate skeletal material of marine life, e.g. the coral Porites skeletal aragonite. For example, by coating the surfaces of such materials with a liquid material capable of being cured or set to a solid, followed by curing or setting and dissolution, e.g.

Abstract: A method of forming a slip cast article is disclosed. The slip cast article is formed in a casting volume of a forming mold, which mold has a portion thereof formed of a meltable organic material. The vehicle of the casting slip used to form the article is drawn off to a level which provides a consolidated casting in the casting volume which contains sufficient vehicle that the casting is resistant to shrinkage. The consolidated casting and the organic mold portion are then surrounded with a porous, liquid drawing media. A high humidity of the vehicle of the casting slip is maintained about the consolidated casting surrounded by the porous, liquid drawing media. The consolidated casting and surrounding liquid drawing media are heated while the high humidity of the vehicle is maintained to a temperature which causes the meltable organic material to melt. The porous, liquid drawing media then draws the melted material away from the consolidated casting.

Abstract: A ceramic molding composition comprising an alcoholate of aluminum or a metal of the fourth sub-group of the Periodic System, a refractory metal oxide and a polyvalent alcohol, an improvement in the formation of a ceramic product wherein a ceramic molding composition is shaped and hardened, which improvement resides in employing the above defined ceramic molding composition.

Abstract: Synthetic resin bodies reinforced with fiber, roving or the like can be made, in accordance with the invention, by impregnating the reinforcing material with synthetic resin and then casting a hardenable liquid around the resulting body to form a mold in situ therefor. The synthetic resin material is thus permitted to harden in the solidified mold material whereupon the mold material is removed.

Abstract: A novel method is disclosed for the manufacture of a hollow graphite-epoxy structural part with high composite density and using tooling that eliminates the necessity of autoclave and similar high external pressure curing equipment. The method of manufacture in part involves the use of a rigid hollow frangible mandrel and superimposed flexible pressure bag element which subsequently develops high internal pressures in the part being processed during composite curing stages.

Abstract: A process for the continuous production of a hose formed and vulcanized on a mandrel, comprising continuously forming and advancing a hollow mandrel, continuously forming said hose about said mandrel and continuously vulcanizing said hose while advancing said hose in axial direction with said mandrel, after said mandrel arrives at a predetermined location continuously destroying said mandrel within said hose, and removing the remnants of said mandrel from said hose. The mandrel may be formed of a brittle material such as sintered metal or of a relatively low melting material and its destruction can be effected by longitudinal severance into strips and/or melting by induced current and/or fragmentation by ultrasound. Alternatively the mandrel may be made of soluble material and subsequently dissolved away. Endless reinforcements may also be circulated and the mandrel formed so as to partially embed said reinforcements. Corresponding apparatus is provided.

Abstract: Method and apparatus for preparing a wax replica of a dental prosthesis is disclosed. The method of the invention is carried out by preparing a composite dental model which includes a base portion, an odontal die projecting from the base portion having a cavity in which the dental prosthesis is to be implanted, and an index pin embedded within the composite dental model. A complementary dental model having an odontal projection defining an occlusal surface for engaging the odontal die is also prepared. The index pin includes an anchor shank portion embedded within the odontal die, an alignment shank portion embedded in the base portion and a radially projecting collar portion disposed in the interface of the base portion and the odontal die. The odontal die and embedded index pin are removed from the base portion of the composite dental model and a die spacer is placed around the alignment shank portion of the index pin.

Abstract: A composition which is hydrophobic but possesses excellent wettability comprising a copolymer of a polysiloxane and an ester of glycidyl alcohol and an organic acid. This copolymer is suitable for the manufacture of ocular membranes worn in contact with the eye which present excellent oxygen permeability and which can be worn for extremely long periods of time and then disposed of.A method of preparing the ocular membranes is disclosed, in which the composition is placed between disposable molds and cured therein. The cured, mechanically and optically finished ocular membranes are recovered by the destruction of said molds and without secondary operations.The ocular membrane is a flexible, oxygen-permeable, membrane, adapted to be inserted on the eye and worn thereon continuously for periods of more than one month.

Abstract: The invention provides a process for making artistic prints on paper, cloth or other sheet material having a three-dimensioned surface texture. A smooth surface plate is first prepared of a waxy composition that is ductile and malleable at ambient temperature, and is also electrically conductive. An artist treats the surface of this plate by engraving and molding to produce a three-dimensional artistic work. An electrically conductive coating is applied to the treated surface and the plate is then coated in an electrolytic bath with a thin film of copper, which constitutes a mold of the artistic work. This copper film is separated from the waxy plate, -tinned, and strengthened by casting onto it a layer of lead. The copper surface of the composite plate is inked or colored with paint, and is then placed on the platen of a printing press having pressure rollers. The sheet material to be printed is placed over the copper surface under a blanket and passed through the press.

Abstract: A process for deposition of polycrystalline silicon from the gas phase on ated carrier bodies of carbon, which comprises assembling the carrier bodies from extremely thin flexible graphite foils, heating the bodies to deposition temperature, while contacting them with a gaseous mixture containing a decomposable silicon compound and, if desired, hydrogen, and separating the deposited silicon from the carrier body, after termination of the deposition process, by mechanical means. The polycrystalline silicon can either be deposited in the form of shaped hollow bodies for use as laboratory equipment or in the semiconductor industries, or it may be processed to monocrystalline materials.

Abstract: A ceramic molding composition comprising an alcoholate of aluminum or a metal of the fourth sub-group of the Periodic System, a refractory metal oxide and an agent selected from the group consisting of diketones of the formula ##STR1## wherein R.sub.1 and R.sub.2 are each independently an aliphatic radical of between C.sub.1 and C.sub.18 carbon atoms or an aromatic radical from C.sub.6 to C.sub.18 carbon atoms, a hydroxycarboxylic acid compound of the formula ##STR2## wherein R.sub.3 is an aliphatic radical of C.sub.1 and C.sub.18 or an aromatic radical from C.sub.6 to C.sub.18, and R.sub.4 is hydrogen or an alkyl radical of C.sub.1 to C.sub.4, and a polyvalent alcohol, an improvement in the formation of a ceramic product wherein a ceramic molding composition is shaped and hardened, which improvement resides in employing the above defined ceramic molding composition.

Abstract: A method of making a high temperature fluted core composite radome structure.

Abstract: A preform mold space is formed by two mold sections spaced from each other. A gem is positioned in the mold space, and a hardenable preform wax-like material is introduced into the mold space and into supporting contact with the gem to thereby form a preform model upon hardening of the wax-like material. The preform model is removed from the mold space and embedded in hardenable embedding material so as to form a mold cavity about the exterior of the preform model upon hardening of the embedding material. Simultaneously with the hardening process the wax-like material is melted and removed from the mold cavity while the gem remains embedded in the mold. A heated molten hardenable metal material is then introduced into the mold cavity. The hardened metal material supportingly engages different facets of the gem and fixedly anchors the latter in the article of jewelry formed by the disclosed method.

Abstract: This invention relates to the making of negatives intended for the production of bodies which contain cavities of predetermined shapes.The term "negative" signifies a disposable core member, for example as used in some molding techniques such as the lost wax process. The negative at least partly matches the cavities which latter form two independent systems of regularly distributed intersecting channels with the channels in any one same system intercommunicating via ducts which are themselves regularly distributed.

Abstract: A castable slip of a bimodal distribution of silicon carbide particles is prepared, the slip preferably containing a water miscible curable resin. A shaped body is cast in a plaster of paris mold which also preferably contains a small amount of a water soluble polymer. The casting and mold are then heat treated to increase the strength of the green casting. In a preferred embodiment of the invention the resin in the slip is cured by the heat treating step. The mold is then removed by decomposing the mold material, preferably by dipping the mold in acid to attack the mold material (e.g. the water soluble polymer or the plaster of paris itself). The cured resin in the casting is sufficiently resistant to attack by the acid to survive the mold removal. In an alternative embodiment the silicon carbide body is heated to a sufficiently high temperature (e.g. 650.degree.-750.degree. C) to slightly oxidize the SiC and to strengthen the green casting.

Abstract: A building form and method of preparing molded articles thereon which comprises molding an article on the casting surface of a building form comprising a casting surface adhered to a water destructible support layer, the said casting surface comprising a water permeable polymeric film, water destructing the said support layer, water penetrating the said casting surface, and removing the molded article.

Abstract: A denture comprising teeth consisting essentially of hard non-hydrophilic polyurethane elastomer imbedded in and chemically bonded to a gum member consisting essentially of soft non-hydrophilic polyurethane elastomer is prepared from a model assembly consisting of a wax replicate denture (artificial teeth imbedded in a wax pattern) mounted on a mouth model, which assembly is usually provided by a dentist or dental technician after a series of dental impressions, bites, and trials with the patient. A female mold is prepared from the model assembly having a cavity conforming to the wax replicate denture which, together with the mouth model after the wax replicate denture has been removed, forms a denture mold. The hard non-hydrophilic polyurethane elastomer teeth are first cast in the cavity of the mold. The casting is then removed and trimmed of its flash down to the gum line to delineate the shape of that portion of the teeth to be imbedded in the gum portion of the denture and replaced in the mold.

Abstract: A method for casting vitreous materials using the lost wax process in which a pattern of the article to be cast is formed with a substance which is vaporized at the casting temperature of the vitreous material. The pattern is embedded in a heat resistant silica compound such as sand which surrounds the pattern to form a casting mold. The sand is contained in a receptacle called a casting shell. The vitreous material is heated to a temperature at which its viscosity is between 20 and 100 poises and the article is cast.

Abstract: An alumina core for investment casting directionally solidified eutectic and superalloy materials consists of a central portion which has porosity which is continuous throughout. The material of the central portion has a micro-structure which is characteristic of alumina grains which have undergone vapor phase transport action. An outer layer of alumina encompasses the central portion and in integral therewith and contains porosity which is discontinuous.

Abstract: A system of making molds for investment casting in which the patterns are formed from, and the sprue form is coated with, polyethylene glycol having a molecular weight in the range of from approximately 1,300 to approximately 1,600, or its equivalent and having admixed therein as a filler powdered graphite, in which the graphite comprises in the range of from about 35 per cent to 60 per cent by weight of the pattern forming material. The patterns are molded to the desired shape, and to include a gate section, and they are adhered to the sprue form in spaced apart relation by fluidizing the gate section end to make a welded connection with the sprue form coating. The mold is then formed about the patterns that are adhered to the sprue form, leaving the pour cup end of the sprue form exposed, to which heat is subsequently applied to sufficiently fluidize the sprue form coating so that the sprue form can be drawn out of the mold thereby leaving the sprue opening.

Abstract: This invention relates to the making of negatives intended for the production of bodies which contain cavities of predetermined shapes.The term "negative" signifies a disposable core member, for example as used in some molding techniques such as the lost wax process. The negative at least partly matches the cavities which latter form two independent systems of regularly distributed intersecting channels with the channels in any one same system intercommunicating via ducts which are themselves regularly distributed.

Abstract: Method is disclosed for preparing a honeycomb insulation structure having its cells partially filled with a low density foam and a high density integral skin completely covering one edge of the honeycomb. Method comprises placing one edge of a honeycomb in an inert material; introducing a foamable or foaming substance into the cells and allowing it to rise from the surface of the inert material until it overflows slightly. The overflowing foam comes into contact with a pressure platen just above the honeycomb thereby forming the high density integral skin. The level of the material in the cell determines the thickness of the void on one edge. Structure has utility in cryogenic storage.

Abstract: The crushability of a ceramic article suitable for use in the casting and directional solidification of advanced superalloy materials is enhanced by utilizing a two-phase mixture of material and inducing microcracks in the material. The crushability is further enhanced by forming the article to include a predetermined porosity content.

Abstract: A denture consisting of teeth anchored in a gum member composed of a unitary mass of non-hydrophilic polyurethane elastomer, the tooth-holding portion of which is hard and the mouth-engaging portion of which is soft is prepared by first casting the teeth-holding portion about the teeth and then casting the gum holding portion onto the tooth-holding portion and curing the denture during which the gum-engaging portion and the tooth-holding portion become integrally chemically bonded into a unitary mass.

Abstract: A method for making a disposable model for a precision investment casting, which comprises casting a naphthalene or para-dichlorobenzene-containing modeling material into a pattern mold at a temperature of 150.degree. C or less, preferably 80 to 150.degree. C and further preferably at a casting speed of 5 to 0.1 kg/second; the modeling material being optionally admixed with a resin selected from the group consisting of polystyrene, polyethylene, polyvinyl acetate and a mixture thereof as a reinforcing material or comprising a mixture of naphthalene or paradichlorobenzene (preferably 80 to 30% by weight), a wax (preferably 20 to 70% by weight) and the resin as mentioned above (preferably 0.5 to 15% by weight on the basis of the whole weight of the modeling material).