Abstract: A charge plate for an ink jet printer comprises a rigid support plate provided with a medially extending elongated slot and an electrode support structure cast in place adheringly against the walls of the slot. The electrode support structure is fabricated from a nonconductive casting resin which is cast against a silicone elastomer mold having a series of upstanding pegs coated with a release agent and an overcoating of conductive epoxy. The casting resin flows around the peg structure and bonds itself to the conductive epoxy coating. The conductive epoxy material transfers from the mold surface to the electrode support structure upon mold separation, so that the casting process produces a series of cylindrical charging electrodes cast in place within charging tunnels in the electrode support structure. The resulting product is subjected to a finishing operation, and flexible printed circuit leads are thereafter attached to the charging electrodes.

Abstract: A reinforcing cord is positioned in a mold cavity for reinforcing an annular article such as a tire by wrapping the cord on an annular spacer band which is supported on a mold core and then placed in the mold. The mold is charged with a liquid polyurethane reaction mixture to form an outer polymeric ring of the annular article which is adhered to the cord and partially cured. The spacer band is removed, the mold closed and charged with additional liquid polyurethane reaction mixture to form an inner polymeric ring of the annular article adjacent the reinforcing cord carried by the outer ring. The partially cured outer ring and the inner ring are then cured to adhere the inner ring to the outer ring with the layer of reinforcing cord encapsulated between the rings. An additional layer of reinforcing cord may be positioned in the article by wrapping another cord around a second spacer band having a smaller diameter than the first spacer band.

Abstract: A ball nut and screw assembly is provided with a molded internal return system for a train of balls drivingly interconnecting the nut and screw. A ball nut with an internal crossover is used as a master mold to produce an imprint mold which positively profiles the helical groove and the cross of the master mold. The imprint mold is positioned in a blank nut and a thermal set resin is supplied to radial openings formed in the blank nut which subsequently hardens into a plug with an internal crossover channel like that of the master mold.

Abstract: The invention relates to the production of spectacle frame parts of synthetic material and in particular to the moulding of spectacle frame faces of synthetic material, for example, of polyurethane.The faces are moulded between two casting half-moulds each comprising a plate having an impression on one surface thereof. Each plate has a substantially equal thickness at every point and is made of a polyolefine. Use of such half-moulds enables the faces of spectacle frames to be directly moulded into their final shape.

Abstract: A method for making decorative concrete blocks which have inlays and which are especially suitable for use as floor or patio tiles. The method involves two steps in which concrete with two different degrees of wetness is employed. As an initial step, a first form, which is configured to define the desired inlaid pattern, is placed on a support. The form is filled with a first charge of concrete, which has the lesser of the two degrees of wetness and is preferably colored, to produce a pattern for the inlay. Thereafter, the concrete in the first form is compacted whereafter the form is removed without delay and the material is allowed to harden. In a further step, a second form, which is configured and dimensioned to surround the concrete inlay pattern, is placed on the support. A charge of concrete with a greater degree of wetness is then poured into the second form until it produces a layer which surrounds the concrete inlay pattern.

Abstract: A method of increasing the adhesion of a cast polymer lens to a resinous lens mold by subjecting the resinous mold material to high internal shear force to alter the molecular structure of the resinous mold material to provide for greater bonding between the mold and lens material.

Abstract: A method is disclosed for forming a retroreflective sheeting having a plurality of retroreflective cube-corner prisms distributed over one of its surfaces such that the prisms are disposed in a planar array having a plurality of zones of prisms having differing angular orientations such that the zones have differing retroreflective brightness when illuminated by a light beam at a high angle of incidence.

Abstract: An improved fishing lure is made by forming a first sample lure, without hooks and accessories, in the exact image of a desired bait fish. This first sample lure, however, will have a tail section or portion so thin that it would be vulnerable to damage when being handled out of the water as well as in the water when being taken by a larger fish. The dorsal and other fins would be, similarly, fragile--if they were to project in their normal swimming manner--when the exact image of the bait is formed. The tail portion of the sample lure is cut off far enough up on the body of the fish to find a substantially thick crossection, and any dorsal or other fins that would be too delicate to survive may be cut off too. A new tail portion is formed having the same profile as that of the original sample lure, and is attached to the body of a modified sample lure.

Abstract: A method for producing in a single casting operation a dental model including a unitary tooth die which incorporates an integral mounting pin. The pin and die form a part of, and are removable from the dental model. Prior to casting the die, a bayonet shaped mounting pin is held in position by a permanent divider which, in turn, is supported in a negative impression of a denture. The die and base are then cast simultaneously, eliminating the need for the more commonly used double casting procedure.

Abstract: An exact replica of a tool for deep drawing, moulding, extruding and the like is manufactured by a method according to the present invention by thermally spraying the wearing surface of the tool to be produced onto a negative replica of the tool to be produced, said last replica being constituted of an easily fusible metal with a lower melting point than the plastic material used for backing up (1) the easily fusible negative replica and (2) the thermally sprayed wearing surface of the tool. According to the method of the invention the wearing surface of the tool can be constituted of steel, carbide or oxide.

Abstract: A shapeable matrix is provided for use in making of graphic art reproductions and in particular as a mold in forming of printing plates and other marking items.

Abstract: The invention is directed to a method of embossing wood grain patterns on fiberboard surfaces. A Mylar sheet is placed between the embossing plate and the coated fiberboard. The Mylar sheet prevents removal of the coating from the fiberboard and still permits good detail for fine embossing.

Abstract: A core holding structure for molds and method of making same. A hollow bushing is locked within a mold so positioned with respect to a cavity in the mold that a rod-like core may be mounted on the bushing to provide a bore for hollow members such as spouts used in the continuous casting of metals. The bushing effects proper spacing of the core from the walls of the mold so that the wall thickness of the finished article is controlled. The mold may be made from a single member or it may be made from a multiple piece mold. Special knock out plate members are used in connection with the one-piece molds to extend the life thereof.

Abstract: Connection of electrical leads to individual charge electrodes in a charge plate structure is facilitated by the integral formation of such leads during the mold stage of formation of a charge plate. An elastomeric mold is formed from a charge plate master coated with a photoresist material and having base area corresponding to the placement of the electrical leads. The elastomeric mold is coated with an electrically conductive resin, and a charge plate is cast in the mold. Upon separation, the conductive resin transfers to the charge plate structure forming charge electrodes. Lapping or grinding the surface of the structure removes excess resin and leaves the electrical leads intact.

Abstract: Thin thermoplastic film is reformed to provide matching elements for surfaces of complex curvature, such as the surfaces of compound or aspheric glass lenses. The film is hot-pressed between the curved surface to be matched and a pressing piece of similar curvature, formed by casting a low-melting-point alloy against the curved surface to be matched.

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: A method and apparatus for reproducing in minute detail a surface underwater. The apparatus consists of a layer of wax supported in a frame for movement into and out of contact with the surface to be reproduced, there being provided means for heating wax material to soften it and means for withdrawing the water from between the wax and surface to be molded to provide a substantially water free surface for molding.

Abstract: Using a highly flowable silicone putty which can be combined with catalysts to set, dentures can be repaired and modified by flowing the putty onto the dentures, allowing it to set while in intimate contact therewith, removing the dentures from the set putty for effecting changes, and subsequently reinserting the dentures in the set putty to effect any necessary changes, modifications or repairs. Prior art practices often used dental stone which had to be chipped away from the dentures when effecting repair or modification.

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: Controlling the release of cast polymeric optical lenses from a resinous optical mold by coating the resinous mold material particles with a release agent before forming the resinous material into a lens mold.

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: Relieved pattern of a resin original pattern plate, which does not exhibit fluidity at transferring temperature and possesses elastic modulus no smaller than 10 kg/cm.sup.2, preferably no smaller than 100 kg/cm.sup.2, is transferred onto thermoplastic resin material having fluidity at the transferring temperature (ASTM D1238, load 21.6 kg) of at least 0.01 dg/min, preferably at least 0.1 dg/min, by pressing the thermoplastic resin material to the original pattern plate under a pressure condition where elastic deformation of the original pattern plate is kept within 10%. The resin original pattern plate is prepared by controlling the photopolymerizable resin composition to adjust its cross-linkability and then photo-polymerizing, whereby the resulting resin original pattern plate possesses an elastic modulus of 10 kg/cm.sup.2 or higher at transferring temperature.

Abstract: Method of preparing polyurethane composite mold by injecting a composite reaction mixture onto a master form in a mold cavity, curing said reaction composite and removing it from the master form in a step-wise process involving a pressure manipulation. Said composite comprises 100 parts by weight inorganic water insoluble inert granular material and about 50 to about 200 parts by weight liquid polyurethane reaction mixture substantially free of volatile solvents.

Abstract: A matrix is used to prepare a mold of an elastomeric material. A polymerizable compound is coated onto a flexible, thin substrate such as Mylar and is placed with compound side in intimate contact with the mold. The compound is cured and is bonded to the substrate. The cured combination is stripped from the mold and is given a metallic coating to improve reflectivity. A clear plastic coating may be applied to protect the metal surface.

Abstract: A method of making a vacuum blanket for vacuum curing elastomeric and plastic materials and more specifically, it relates to making a vacuum blanket by spray coating a polyurethane liquid reaction mixture.

Abstract: A method of molding wherein a mold for shaping a material to be molded is formed by casting a first mold base portion formed of a bulk material such as Portland cement, carbon, graphite or castable ceramic material and the like to define a mold cavity, and coating the mold cavity with a first metallic layer. Upon the metallic first layer, there is deposited a second hard surface layer formed of a material such as the carbides, nitrides, and oxides of tungsten, titanium, boron, silicon and aluminum.

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: This invention provides a process for preparing artificial leather bands or belts, particularly those suitable for use as watch bands or straps which are characterized by bearing close resemblance to natural leather in the appearance, feeling and touch and toughness of the product, inexpensive production cost and easiness in the production control.

Abstract: Fishing lures are made by molding or casting in a two part mold. The lower part of a mold form is first filled with mold material, and a specimen of bait fish is partially embedded in this lower part of the mold, with suitable means for release of the bait fish if necessary. Appurtenances such as hooks, suitable to the lure, are also partially embedded in the lower part of the mold, at strategic locations along the bait fish, as is a metallic eye adjoining the head of the bait fish. Other devices for filling and venting the mold may also be added at this time. The upper part of the mold form is then filled with mold material on top of the bottom part -- with suitable means for separating the two parts if necessary -- until the bait fish and all of its appurtenances are completely covered. When the mold material is set, the parts are separated, and the specimen of bait fish and all of its appurtenances are removed.

Abstract: A method of lining a pipe with settable material including the steps of arranging the pipe with its longitudinal axis inclined at an angle to the horizontal, introducing a selected amount of liquid material into the pipe at a predetermined rate so that the liquid material flows down along the pipe, shifting the pipe to a horizontal position and spinning the pipe about its axis to distribute the material, spinning continuing until the material has set. The method is particularly applicable for lining pipes with polyurethane. For pipes with end flanges end faces of the lining material can be formed integral with the lining.

Abstract: Mercaptoalkanoic acids and thiodialkanoic acids are reacted with a poly(oxyalkylene)-polyol to form poly(oxyalkylene)-polyester-poly(monosulfide)-polythiols which are useful as encapsulating materials and mold compositions when oxidatively coupled or cured. In one embodiment, a polymeric reaction product, either in the uncured state or partially cured state, is used for the preparation of flexible molds from which regularly or irregularly shaped objects can be made.

Abstract: A method for making a composite mold utilizing room temperature vulcanizing silicone rubber for the surface of the mold and room temperature vulcanizing polyurethane rubber for the rest of the mold.

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: Method of making a cylindrically shaped, partially collapsible, foam mandrel to be used for the manufacture of hollow resin impregnated fiber tubes. The mandrel is made of a substantially rigid foam cylindrical member, an extractable bar, and a means for aiding in collapsing the cylindrical member such as a groove. Both the extraction bar and the means for aiding in collapsing the cylindrical member are disposed in and along the entire length of the cylindrical member such that the longitudinal axis of the bar, the means for collapsing the cylindrical member, and the axis of the cylindrical member preferably lie on the same plane.The method of manufacturing the aforementioned mandrel comprises the steps of first providing a circular mold having upper and lower sections. A groove-forming member is placed in the lower section and the extraction bar is placed on the upper section. Foam forming material is poured into the lower section which is then covered with the upper section.

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 process for preparing a mold by preparing a slurry of refractory powder in a binder solution comprising silica sol and monomethyl triethanol ammonium silicate or tetraethanol ammonium silicate at a mole ratio of SiO.sub.2 /M.sub.2 O of 10 to 22 and a mole ratio of SiO.sub.2 /NR of 9 to 28 wherein M represents Li or Na and NR represents monoethyl triethanol ammonium hydroxide or tetraethanol ammonium hydroxide, and repeating an overcoating of said slurry and a refractory powder by coating said slurry on a pattern, sanding said refractory powder on the coated pattern and drying it to form a green mold, separating said green mold from said pattern and calcining said green mold.

Abstract: Continuous concrete pipe is produced in an open trench by drawing a sled along the trench. The sled has a fresh concrete intake chute which supplies the concrete to a pipe-forming mechanism that generates the pipe. The lower pipe half is supported by the trench. To support the upper pipe half, a plastic material is given a convex shape complementary to the concave interior of the pipe. The plastic material is formed over a convex mandrel carried by the sled forward (in the direction of movement of the sled) of the intake means so that the plastic material hardens before contacted by wet concrete from the intake means. The mandrel extends rearwardly past the intake means to provide support for the plastic mold while the pipe is formed. Alternative ways for making the plastic mold are described.

Abstract: This invention relates to a flexible mold and a process of making wherein a composition or laminate is formed to give the mold the desired solvent resistance and yet maintain its flexibility.

Abstract: Method of producing a three-dimensional pattern on a resin article which comprises producing a two-dimensional pattern on a flexible sheet or web of a heat-foamable plastic material, applying heat to cause said plastic material to expand, thus forming a three-dimensional pattern, applying a release coating to the three dimensional surface of said flexible sheet or web, contacting said three-dimensional surface with a resin plastisol, curing said resin plastisol in contact with said surface to form a solid resin object and removing said flexible sheet or web from said cured resin object to expose the three-dimensional pattern thereon.

Abstract: A reinforced silicone rubber mold composite is formed by bonding a silicone mold member to a rigid laminated member. The silicone rubber mold member is cast to conform to a desired pattern and its back surface is bonded to a flexible open-celled foam by means of a layer of the silicone rubber being impregnated into a layer of open cells of the foam which are adjacent to the back surface of the silicone rubber mold member. The laminated member consists of the flexible open-celled foam having the layer of open cells impregnated by the silicone rubber and the remaining open cells impregnated by a cured epoxy resin.

Abstract: One bathtub of an identical series of bathtubs has its surface protruding drain and overflow fittings removed, the exposed surfaces of the existing bathtub are lined with Plasterine of a thickness equal to a fiberglass liner to be full surface glued to the existing tub and a fiberglass working mold thickness, a layer of wet plaster of Paris is applied to the Plasterine lined bathtub, reinforced and dried to form an initial mold which is then removed from the Plasterine lined existant bathtub. The outer surface of the plaster of Paris initial mold is waxed and buffed to a high gloss finish. A thin fiberglass and resin working mold is layed up on the outer surface of the initial mold after applying a mold release agent. The working mold is finished off with a gel coat which, upon hardening, is buffed and waxed.

Abstract: A molding plate for use in molding printing plates. A type-form plate bearing raised printing or indicia is coated with graphite and placed in a mold cavity with the printed surface being at an angle to the vertical and facing upwardly. A liquid thermosetting resin containing reinforcement is poured into the mold cavity and air is expelled from the upper end of the cavity. The resulting cured thermosetting resin plate has recessed printing impregnated with graphite and serves as a molding plate for forming printing plates from rubber or other materials.

Abstract: The cost of a silicone rubber mould is reduced by making it partly from uncured, liquid, castable, silicone rubber and partly from compatible, reclaimed silicone rubber particles. The latter are treated, e.g., with a swelling agent, to decrease their specific gravity below that of the liquid, silicone rubber. When the two rubbers are amalgamated in a mould having an exposed surface of a master to be reproduced, the particles float away from the surface of the master leaving the liquid, silicone rubber, which is permitted to cure, in contact therewith. After curing the resultant silicone rubber mould is stripped from the master.

Abstract: Reproductions of works of art or other artifacts in which the surface irregularities are reproduced as well as the colors of the original, are prepared by forming a mold which reproduces in negative form the surface irregularities of the original, preparing a transparent moldment in said mold, preparing a photographic reproduction of the original to the same scale as the moldment, and joining the moldment and the reproduction in registry. The mold may be prepared either by casting on the original work of art or artifact to be reproduced, or on a reproduction prepared manually by a skilled artisan, the latter technique making it possible to vary the scale of the reproduction. Where the scale of the mold is different from that of the original, the scale of the photographic reproduction is changed correspondingly.

Abstract: A method of fabricating a printing block and a printing block produced thereby wherein at a support there is produced a picture or image to be printed by application of a color mass, the applied color or ink mass is covered with a powder layer, the applied color mass being in a state permitting penetration of the powder granules, and then a printing block carrier material is applied in such a state to the support carrying the color mass provided with the adhering powder layer that the powder particles likewise can penetrate into such carrier material, so that after hardening of the printing block carrier material the powder granules are embedded in such material, then the support is separated from the hardened printing block powder material and thereafter the color mass adhering to the printing block carrier material is removed.

Abstract: A fluid-releasable mold for forming shaped ware including a porous mold body comprising at least 70% alumina, up to 15% ball clay and up to 15% talc is disclosed. A mold face is formed on one surface of the mold body and fluid-permeable conduit is provided in communication with a second surface of the mold body with means for sealing the fluid-permeable conduit to the second mold body surface to prevent the escape of fluid from the conduit other than through the mold body and out the mold face. The arrangement obviates the problem of gradual loss of porosity which has heretofore limited the service life of fluid-release molds of alumina, ball clay, and talc.

Abstract: A silicone rubber mold is prepared by applying a room temperature curable, dough-like silicone composition to an area of a pattern which is vulnerable to high stress and thereafter the remainder of the pattern is coated with a flowable silicone composition which is curable at room temperature. The mold is cured and ultimately separated from the pattern being copied. The resulting silicone rubber molds may be used for high frequency flow molding.

Abstract: This invention involves a method of making a unitary pattern assembly which is useful in forming an investment shell mold having an integral base for the conventional and directional solidification of molten metals and alloys. It comprises providing a yoke having a pattern capturing means and two leg members, providing a mold structure having a cavity comprising a pattern section and base section, positioning the mold structure and yoke to expose the capturing means and leg members to the pattern section and base section, respectively, forming a pattern having a base integral therewith in the cavity and removing the mold structure from the pattern and integral base. A unitary pattern assembly comprising a yoke and pattern, having an integral base, fixedly captured therein is obtained. The method is especially suitable for making a pattern assembly useful in the production of gas turbine engine blades by the "lost wax" process.

Abstract: A method of forming a plastic microwave feed horn by first forming a mandrel which is thereafter incorporated into a mold apparatus.

Abstract: A method of producing synthetic resin spinnerettes. Vertically extending synthetic filaments are mounted on a frame structure and placed in a mold. A thermoplastic or themosetting resin is poured into the mold and allowed to set. The molded body is removed from the mold and the filaments are removed therefrom to leave orifices.