Abstract: A contoured article having three dimensional surface effects is disclosed herein, such as a headliner or floor covering for a vehicle. The contour of the article and at least one three dimensional decorative surface are incorporated into the article during molding. The three dimensional surface preferably is an exact replica of the surface of a textile product. Further, the final article may be surface decorated, if desired. A process for producing a contoured article having a three dimensional decorative surface is also disclosed and claimed herein. The process involves the provision of a master mold, the cavities of which define both the contour and the three dimensional surface design. A foamable composition is cast into one section of the master mold after which the mold sections are brought into register while the composition is fused or cured in situ, conforming to the contour and three dimensional surface cavities of the mold.

Abstract: A method for selecting replacement valve stems to replace corresponding defective valve stems including the steps of selecting a set of pattern valve stems representing the replacement stems and employing such pattern valve stems to construct a mold having coded cavities defining the contour of such pattern valve stems. Fluid plastic is then poured into the cavities of such mold while the mold is spun to force such plastic positively into such cavities under the influence of centrifugal force, the valve stem models formed in such cavities then cured and removed from the mold. The coded valve stem models are then collected together on a display board or the like to be displayed in a market area for viewing by customers so a customer desiring to replace a defective valve stem may compare such defective valve stem with the model valve stem to obtain a code designation to indicate the replacement valve stem corresponding with such defective valve stem.

Abstract: A three dimensional, decorative material is disclosed and claimed herein, having good dimensional definition and capable of virtually unlimited design. A process for producing the three dimensional composite is also disclosed and claimed herein. The process originates with the manufacture of a master mold which can be produced with virtually any design, and preferably is made into a continuous belt. An elastomeric foam composition is then cast into the cavities of the master mold and fused in situ, whereby a three dimensional material is produced. Thereafter, a suitable adhesive is applied to the design side of the material and flock fibers or some other decorative substances are deposited thereon. After curing of the adhesive, any excess fibers are removed, and the material may be cut into suitable lengths, provided with a contact adhesive on the reverse side or the like.

Abstract: A method of making a resilient storage insert for holding fragile compone comprising the steps of first vacuum forming a sheet of flexible acrylonitrile butadiene styrene in a male die and then placing said vacuum-formed sheet in a female die, then filling the underside of said vacuum-formed sheet with polyurethane foam material and then curing said polyurethane foam material.

Abstract: Polymeric replica molds formed from certain specific polymeric compositions are disclosed. The polymeric compositions impart properties to the replica molds which allow the casting of high-quality plastic optical components such as ophthalmic lenses.Among the polymeric compositions which have been found useful are: (1) cross-linked polymethyl methacrylate; (2) a copolymer of 99-20 parts methyl methacrylate and 1-80 parts acrylonitrile, preferably but not necessarily cross-linked; (3) cross-linked polystyrene; (4) a cross-linked copolymer of 90-10 parts styrene and 10-90 parts acrylonitrile; and, (5) a cross-linked copolymer of 90-10 parts styrene and 10-90 parts methyl methacrylate.Replication processes including the steps of forming the polymeric replica molds described herein and subsequently using them in the casting of plastic lenses from materials such as polymerized allyl diglycol carbonate are also disclosed.