Forming Mold From Fluent Material Patents (Class 264/225)
  • Patent number: 7232301
    Abstract: A machine for the manufacture of flexible moulds is described, in particular for the obtainment of lipsticks or the like, which comprises a female mould including at least one moulding cavity fillable with a plastic fluid, a male mould including at least a male stem and means to insert said male stem into said cavity of the female mould after the same has been filled with said plastic fluid and to extract it from the same after a prefixed cooling period suitable to transform said fluid plastic into a flexible mould.
    Type: Grant
    Filed: April 28, 2004
    Date of Patent: June 19, 2007
    Assignee: Intercos S.p.A.
    Inventor: Nadia Avalle
  • Patent number: 7225853
    Abstract: A thermoforming apparatus having a mold with an internal vacuum chamber and a quench for cooling a thermoplastic sheet while it remains on the mold. Because the quench cools the sheet, conventional cooling lines are eliminated from the mold. A preferred process of using the thermoforming apparatus includes drawing a heated sheet over the mold, creating a partial vacuum in the vacuum chamber of the mold to maintain the sheet on the mold and quenching the sheet on the mold in a quenching tank. A preferred process of manufacturing a mold with an interior vacuum chamber includes forming an impression of the mold in a casting media, suspending a vacuum line or vacuum cabinet within the impression and pouring molten material around the vacuum line or vacuum cabinet to form the mold at least partially surrounding the vacuum line or vacuum cabinet. Vacuum holes are drilled through the mold from the mold face to the vacuum chamber.
    Type: Grant
    Filed: March 24, 2004
    Date of Patent: June 5, 2007
    Assignee: Corvac Composites, LLC
    Inventor: James Richard Fitzell, Jr.
  • Patent number: 7217335
    Abstract: A method of manufacturing a hearing aid preferably includes the steps of: placing a moldable material in the ear canal of a patient to cast a form; using the form to form a hollow shell with an outer surface that approximates the shape of the patient's ear canal, the shell being of a soft polymeric material providing a mounting member; mounting electronic hearing aid components to the mounting member; joining the mounting member to the hollow shell to define a mold cavity; and filling the shell with a soft polymeric material that substantially encapsulates at least one of the electronic components and bonds to the mounting member, wherein the combination of shell, electronic components and soft polymeric material define a soft structure that is compliant to ear canal movement during use.
    Type: Grant
    Filed: February 23, 2004
    Date of Patent: May 15, 2007
    Assignee: Softear Technologies, L.L.C.
    Inventors: Roger P. Juneau, Lynn P. Creel, Edward J. Desporte, Michael Major, Gregory R. Siegle, Kelly M. Kinler
  • Patent number: 7182890
    Abstract: The invention relates to a matrix suitable for use in the replication of a plastic element having a positive microstructure, comprising a first wear-resistant layer that is supported by a carrier element, wherein the matrix comprises a heating means for supplying electrical heat energy through the wear-resistant layer or carrier element. The invention further relates to a plastic element producing machine and a method for the manufacture of a plastic element having a surface with a positive microstructure.
    Type: Grant
    Filed: December 2, 2004
    Date of Patent: February 27, 2007
    Assignees: Gyros Patent AB, Åmic AB
    Inventors: Per Ove Öhman, Lars Rune Lundbladh
  • Patent number: 7175793
    Abstract: A realistic three-dimensional replica casting of naturally occurring samples of wood, rock and marine specimens produces realistic appearing landscape or indoor light modules that can simulate flickering candles in nightclubs and restaurants. The method employs a two-part barrier mold technique enabling production of an exact copy of the whole, full bodied, original specimen and includes a lamp unit pattern for creating a three dimensional space for containing a lamp module that is positioned adjacent a relatively flat face of the replica of the natural specimen. The final casting is made of fortified cement that is permanently stained with metallic salts in an HCL solution producing the desired coloration matching that of the original specimen while masking the color of the concrete. The replica is solid and heavy and need not be attached to the ground during outdoor use to maintain it in place, due to the weight of the concrete.
    Type: Grant
    Filed: June 15, 2004
    Date of Patent: February 13, 2007
    Inventor: H. David Reed
  • Patent number: 7160494
    Abstract: A method for facilitating the fabrication of a hard cover for an article is provided. The method includes positioning shrinkable material over at least a portion of the article and shrinking the shrinkable material to form a fitted cover for the portion of the article. A layer of molding material is applied overlying the fitted cover to form a hard cover for the portion of the article. A method for facilitating fabrication of a first article from a second article is also provide. The method includes positioning shrinkable material over at least a portion of the second article and shrinking the shrinkable material to form a fitted cover for the portion of the second article. A first layer of molding material is applied overlying the fitted cover to form a mold. The mold has a surface which is a negative impression of at least a portion of the fitted cover. The mold is removed from the fitted cover and a second layer of molding material is applied overlying the surface of the mold to form the first article.
    Type: Grant
    Filed: February 27, 2004
    Date of Patent: January 9, 2007
    Inventor: Karl R. Meyer
  • Patent number: 7153456
    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.
    Type: Grant
    Filed: April 26, 2002
    Date of Patent: December 26, 2006
    Assignee: GourdCraft Originals, Inc.
    Inventor: Priscilla Ann Wilson
  • Patent number: 7125510
    Abstract: Fabrication of a microstructure device includes assembling a mold component and a mold body to form a device mold for the microstructure device. The microstructure device is cast from the device mold, then the mold component is removed from the microstructure device. The microstructure device is then released from the mold body.
    Type: Grant
    Filed: February 11, 2003
    Date of Patent: October 24, 2006
    Inventor: Zhili Huang
  • Patent number: 7097799
    Abstract: A method of forming prosthetic sockets is provided that first creates a negative mold of the patient's residual limb while it is disposed in a positive flexion position. The mold is then removed and shaped to permit the desired range of flexion when the mold is repositioned on the residual limb. A second cast is made of the residual limb that incorporates the mold. A positive model of the residual limb is then formed, from which test or definitive sockets may be formed. The present method further lends itself to the formation of sockets using a cast-in-place methodology while the limb is disposed in a positive flexion position.
    Type: Grant
    Filed: February 23, 2004
    Date of Patent: August 29, 2006
    Inventor: Russell F. Burton
  • Patent number: 7049385
    Abstract: The present invention relates to the use of C2–C24 aliphatic diols, preferably 1,2 propane diol as a thixotropic enhancing diluent in moisture curable organosiloxane compositions, especially in the presence of silicone-polyether block copolymer thixotropes and to the application of these compositions on vertical substrates.
    Type: Grant
    Filed: February 11, 2003
    Date of Patent: May 23, 2006
    Assignee: Rhodia Inc.
    Inventors: Steven Eric Heilman, Brian Patrick Bayly
  • Patent number: 6986857
    Abstract: This invention relates to a method for preparing at least one mold part of a two-part mold useful for transferring a hydrophobic top coat from a mold onto an optical substrate. Further, the invention relates to a method for easily transferring a hydrophobic top coat from a mold onto the anti-reflecting coating of a coated optical substrate. Additionally, the invention relates to a method which provides improved adhesion of the hydrophobic top coat onto an optical substrate and in particular onto an anti-reflecting coating of a coated optical substrate. The invention also discloses a mold part useful in such methods.
    Type: Grant
    Filed: June 19, 2003
    Date of Patent: January 17, 2006
    Assignee: Essilor International Compagnie Generale D'Optique
    Inventors: Karl Arthur Klemm, Julie Anne Fairbank
  • Patent number: 6979419
    Abstract: A print pad for printing on hard surfaces is made by first forming a mold having a textured surface, then forming the print pad in the mold. The textured surface of the mold is made by first manufacturing a sheet of plastic the surface of which has the desired texture, then using a thermoforming process to shape the plastic into the mold.
    Type: Grant
    Filed: March 6, 2003
    Date of Patent: December 27, 2005
    Inventor: Robert Cameron
  • Patent number: 6971171
    Abstract: The present invention provides a method for manufacturing an ink jet recording head utilizing ink bubbling by heating of an exothermic resistor to thereby eject ink and a method manufacturing the same, including the steps of: preparing a substrate provided with the exothermic resistor; applying such first resin on the substrate as to provide a first mold shape for forming the nozzle channel and the movable member; forming the first mold shape using the first resin; applying, on the substrate, second resin over the first mold shape for forming the nozzle channel and the movable member; and removing the first mold shape. By this method, the movable member is formed in the nozzle channel between the ink inlet and the exothermic resistor to thereby provide a high-density, high-accuracy ink jet recording head which can improve a frequency response while maintaining proper discharge performance.
    Type: Grant
    Filed: August 22, 2003
    Date of Patent: December 6, 2005
    Assignee: Canon Kabushiki Kaisha
    Inventors: Hirokazu Komuro, Masashi Miyagawa, Yoshinori Misumi, Masahiko Kubota, Hiroyuki Sugiyama, Ryoji Inoue
  • Patent number: 6936204
    Abstract: A thermoplastic molding composition for making a molded article comprising (i) a polymer component selected from the group consisting of polyethylene terephthalate, a copolyester of polyethylene terephthalate, and a combination of polyethylene terephthalate and a copolyester of polyethylene terephthalate, and (ii) a polymer additive comprising one or more than one hydroxylic compound comprising from 3 to about 8 hydroxy groups. The amount of one or more than one hydroxylic compound is sufficient to decrease the level of acetaldehyde in the molded article that would be present without including the one or more than one hydroxylic compound in the thermoplastic molding composition. A method for making a molded article with decreased levels of acetaldehyde comprising, first, providing a thermoplastic molding composition according to the present invention, and, second, injection molding the thermoplastic molding composition to form a molded article.
    Type: Grant
    Filed: October 29, 2001
    Date of Patent: August 30, 2005
    Assignee: Color Matrix Europe Ltd.
    Inventor: Sahar Al-Malaika
  • Patent number: 6899838
    Abstract: A method of forming a device including a plurality of micron or sub-micron sized features is provided. A master having a surface contour defining a plurality of features is provided. The surface contour of the master is coated with at least one layer of material to form a shell. The master is removed from the shell to form a negative image of the surface contour in the shell. The negative image in the shell is filled with material, for example, polycarbonate, polyacrylic, or polystyrene, to form a device having features substantially the same as the master. The negative image may be filled using injection molding, compression molding, embossing or any other compatible technique.
    Type: Grant
    Filed: July 12, 2002
    Date of Patent: May 31, 2005
    Assignee: Becton, Dickinson and Company
    Inventor: Alexander G. Lastovich
  • Patent number: 6887915
    Abstract: The present invention relates to a molding material for the precision casting and dead-mold casting of metals or metal alloys comprising plastic and/or carbon aerogels, and a process for the preparation of such molding materials. The molding material comprises highly porous open-cell plastic and/or carbon aerogels, obtainable by the sol-gel polymerization of organic plastic materials, optionally followed by partial or complete pyrolysis of the plastic aerogel obtained.
    Type: Grant
    Filed: May 30, 2003
    Date of Patent: May 3, 2005
    Assignee: DLR Deutsches Zentrum fur Luft-und Raumfahrt E.V.
    Inventors: Lorenz Ratke, Jochen Fricke
  • Patent number: 6884370
    Abstract: The invention relates to a matrix suitable for use in the replication of a plastic element having a positive microstructure, comprising a first wear-resistant layer that is supported by a carrier element, wherein the matrix comprises a heating means for supplying electrical heat energy through the wear-resistant layer or carrier element. The invention further relates to a plastic element producing machine and a method for the manufacture of a plastic element having a surface with a positive microstructure.
    Type: Grant
    Filed: August 2, 2002
    Date of Patent: April 26, 2005
    Assignees: Amic AB, Gyros AB
    Inventors: Per Ove Öhman, Lars Rune Lundbladh
  • Patent number: 6881370
    Abstract: A method for facilitating the fabrication of a hard cover for an article is provided. The method includes positioning shrinkable material over at least a portion of the article and shrinking the shrinkable material to form a fitted cover for the portion of the article. A layer of molding material is applied overlying the fitted cover to form a hard cover for the portion of the article. A method for facilitating fabrication of a first article from a second article is also provide. The method includes positioning shrinkable material over at least a portion of the second article and shrinking the shrinkable material to form a fitted cover for the portion of the second article. A first layer of molding material is applied overlying the fitted cover to form a mold. The mold has a surface which is a negative impression of at least a portion of the fitted cover. The mold is removed from the fitted cover and a second layer of molding material is applied overlying the surface of the mold to form the first article.
    Type: Grant
    Filed: March 5, 2002
    Date of Patent: April 19, 2005
    Inventor: Karl R. Meyer
  • Patent number: 6866803
    Abstract: A slip casting mold includes a water absorption layer having self water absorption capability and substantial water resistance. With the water saturation percentage of the water absorption layer being controlled, a slurry layer is deposited in the slip casting mold mainly under capillary attractive forces of the slip casting mold. The water absorption layer comprises an open porous body which is manufactured by stirring a mixture of an epoxy compound having at least one epoxy ring in one molecule, a hardener for reacting with the epoxy compound to harden the epoxy compound, a filler for developing self water absorption capability and mold releasability, and water into an O/W-type emulsion slurry, and casting the emulsion slurry into a mold impermeable to water, hardening the emulsion slurry in the mold while containing water.
    Type: Grant
    Filed: July 10, 2000
    Date of Patent: March 15, 2005
    Assignee: Toto Ltd.
    Inventors: Akio Matsumoto, Takeshi Sato, Yoshifumi Misumi, Akira Hirayama, Katsuhiro Hasebe, Yoshinori Yamashita
  • Patent number: 6860714
    Abstract: An airfoil for an internal combustion engine, such as a gas turbine, formed by use of a preform. The airfoil includes: an outer surface forming the foil shape; and a plurality of craze-free cooling passages extending through the airfoil. In the preferred embodiment, a root on the airfoil joins the airfoil to the hub of a gas turbine vane assembly. Also, in the preferred embodiment, the gas turbine vane assembly is adapted to receive replaceable airfoils.
    Type: Grant
    Filed: December 30, 2002
    Date of Patent: March 1, 2005
    Assignee: General Electric Company
    Inventors: Thomas Francis McNulty, Frederic Joseph Klug, Shyh-Chin Huang, Michael Francis Xavier Gigliotti, Jr.
  • Patent number: 6808667
    Abstract: A contoured wall and method is disclosed for creating the contour and appearance of a wall formed from individual assembled units such as stones. The wall is formed from a plurality of mating form liners each having a reciprocal contoured surface to that of the desired stone wall. The wall is formed from hardenable construction material such as concrete poured between two mold members with the form liners attached to at least one of the mold members. Each of the form liners has a lateral relief mold face adapted to provide a molded surface having the contour of a stone wall. Each lateral relief mold face of the form liners has a latticework non-linear mortar-forming interlocking portion surrounding stone-forming recessed portions. The form liners are positionable in a plurality of arrangements wherein the interlocking portions and recessed portions along the mating edge of each form liner mate along mating edge of the adjacent form liner to form a continuous lateral relief mold face.
    Type: Grant
    Filed: November 5, 2002
    Date of Patent: October 26, 2004
    Assignee: Concrete Design Specialties, Inc.
    Inventors: Peter Anthony Nasvik, Paul Christian Nasvik
  • Patent number: 6805819
    Abstract: A cylindrical concrete receiver 10 is caused to project from a top section 3 of a body section 11 forming a frame 2. When concrete 5 is filled in the body section 11, part of the concrete 5 is caused to overflow inside the concrete receiver 10 and then, pressure is applied to the concrete 5 overflowed in the concrete receiver 10 by a weight 12.
    Type: Grant
    Filed: September 9, 2002
    Date of Patent: October 19, 2004
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Eiji Tsuyuki, Koujiyu Matsumoto, Noriaki Tamasaki
  • Patent number: 6800234
    Abstract: This disclosure relates to a method for making a polymeric article mold, a method for making a polymeric article with that mold, and improved surface topography features for a polymeric article. A prototype article is formed and then coated with a thin conductive layer. The coated prototype article is then electroformed until nickel plated to a sufficient depth to define a nickel plating tool. After the prototype article has been removed from the mold face of the nickel tool, the tool can be used as a mold for forming finished polymeric articles which replicate the original prototype article. The use of fine topography features such as a dense upstanding stem array on the surface of the prototype article facilitates accurate and complete electroforming by increased surface area presentation. The disclosure also presents improvements to microreplicated surface structures such as stem arrays.
    Type: Grant
    Filed: November 9, 2001
    Date of Patent: October 5, 2004
    Assignee: 3M Innovative Properties Company
    Inventors: Dennis E. Ferguson, James J. Kobe, Bradley D. Zinke
  • Patent number: 6796016
    Abstract: An injection mould which comprises at least five modules aligned with each other. The five modules correspond to a first mould module and a second mould module to form a product cavity, a drive module for driving of sliders, an engaging module adapted, by application of a force, to prevent dividing between the first and the second mould module when introducing product material into the product cavity, and an ejector module for ejecting a completed product from one of the first and the second mould module. The method for making injection moulds comprises the steps of receiving a product pattern, defining function holes and function recesses, and defining, separate from and parallel to the construction of function holes and function recesses, a product cavity and the parting plane of the mould. Moreover the method comprises the step of mechanically machining a plurality of modules essentially simultaneously.
    Type: Grant
    Filed: January 7, 2002
    Date of Patent: September 28, 2004
    Assignee: Nolato AB
    Inventor: Lars Persson
  • Patent number: 6787087
    Abstract: A method of fabricating a PVC ornamental article having effects of imitated materials includes steps of: (a) mold casting: making a prototype of a desired ornamental article, exploding said prototype into a plurality of blank elements, coating said blank elements with silicone to form hollow silicone molds, injecting a wax material into said hollow silicone molds to obtain a wax object, taking out said wax object for trimming and electroplating said wax object, and melting said wax object to obtain a mold; (b) blank formation: adding colorants into said PVC plastic material and mixing said colorants to obtain desired colors, injecting said PVC plastic material into said mold, utilizing centrifugal force to affix said PVC plastic material onto an inner wall of said mold, and removing molded PVC from said mold to form a blank by force before said molded PVC dries, filling a filler into said blank to increase hardness; and (c) assembly: assembling blanks together and joining the blanks with other decorations to
    Type: Grant
    Filed: March 17, 2003
    Date of Patent: September 7, 2004
    Inventor: Paul Chang
  • Patent number: 6783717
    Abstract: A process of making a high precision microcontact printing stamp in which an elastomeric monomer or oligomer is introduced into a mold wherein a photoresist master imprinted with a microcircuit design in negative relief is predisposed. The monomer or oligomer is cured at a temperature no higher than about ambient temperature whereby a distortion-free microcontact printing stamp having the microcircuit design of the photoresist master in positive relief is formed.
    Type: Grant
    Filed: April 22, 2002
    Date of Patent: August 31, 2004
    Assignee: International Business Machines Corporation
    Inventors: Gareth Hougham, Peter Fryer, Ronald Nunes, Mary Beth Rothwell
  • Patent number: 6770340
    Abstract: A method for the production of a multiple phase composite material, wherein the composite material includes a major phase component and at least one minor phase component. The major and minor phase components are arranged in a desired predefined morphological structure in which the major phase component and the minor phase components have predefined size and shape characteristics. The method involves supplying the major phase component to a chaotic mixer (10) in a controlled manner and supplying the minor phase components to the chaotic mixer (10) in a controlled manner. Within the chaotic mixer (10) the major phase component and minor phase components undergo mixing according to controlled parameters to controllably and progressively develop predefined desired morphologies. Resulting structures are also provided.
    Type: Grant
    Filed: September 25, 2001
    Date of Patent: August 3, 2004
    Assignee: Clemson University
    Inventors: David A. Zumbrunnen, Ojin Kwon
  • Patent number: 6764630
    Abstract: A resin (61) as a material of a resin mold is injected in a second resin filling space (57) from a resin injection hole (51) provided in a second back surface reinforcing member (50). When the resin overflows from a resin overflow hole (52), the injection of the resin is stopped, followed by curing of the resin. During the operation of the resin filling step, since a downward load equivalent to a total of a weight of the resin injected in the second resin filling space and the injection pressure is applied to the master model (30), there is a possibility that the master model be deflected downwardly; however, in actual, since the back surface of the master model is overall supported by the temporary filler (59), the master model is not deflected downwardly.
    Type: Grant
    Filed: August 22, 2002
    Date of Patent: July 20, 2004
    Assignees: Honda Giken Kogyo Kabushiki Kaisha, Forma Co., Ltd.
    Inventors: Hiroshi Shirakawa, Isao Nishigaki, Masami Kunii
  • Publication number: 20040134588
    Abstract: A method for producing a molded body firmly bonded to a grained molded skin by inserting a spatially conformed, elastic skin having a graining or structuring on the inside into a receiving mold open on one side of a tool bottom part. A liquid plastic film that forms the molded skin after hardening is then applied to the grained inside of the elastic skin. The molded skin is then back-foamed, the foamed plastic firmly bonding with the molded skin. Subsequently, the entire assembly of elastic skin, molded skin, and molded body is removed from the receiving mold of the tool bottom part. Finally, the elastic skin is stripped away from the molded skin that is firmly bonded to the molded body, a graining or structuring remaining on the surface of the molded skin.
    Type: Application
    Filed: November 18, 2003
    Publication date: July 15, 2004
    Inventors: Andreas Gerken, Gunter Vogt
  • Patent number: 6761789
    Abstract: A hearing aid instrument of the in-the-ear type (and preferably CIC) provides a receptacle with electronic hearing aid components mounted thereto. The receptacle has a cavity for holding electronic components (eg. battery, microphone, amplifier). A soft polymeric body is preliminarily formed by encapsulating a plurality of the electronic hearing aid component shaped inserts. The body is soft and is shaped to conform to the ear canal of the user. After forming, the insert is removed to provide an insert cavity that can carry electronic components. The soft polymeric body and encapsulated electronic hearing aid components define a soft structure compliant to the ear canal during use and that is substantially solid and free of void spaces between at least some of the components and the ear canal.
    Type: Grant
    Filed: March 11, 2002
    Date of Patent: July 13, 2004
    Assignee: Softear Technologies, L.L.C.
    Inventors: Roger P. Juneau, Lynn P. Creel, Edward J. Desporte, Michael Major, Gregory R. Siegle, Kelly M. Kinler
  • Patent number: 6699419
    Abstract: A molding process that uses a textured interfacial layer to isolate the surface of a mold from the surface of a composite article produced with the mold. A solution is deposited on the mold surface to form the interfacial layer, whose surface opposite the mold is textured. The texture of the interfacial layer is then transferred to the surface of the composite article produced with the mold. After demolding, the interfacial layer adheres to the article as a protective coating, but can be readily removed from the article to expose an underlying textured surface of the article.
    Type: Grant
    Filed: June 5, 2000
    Date of Patent: March 2, 2004
    Assignee: General Motors Corporation
    Inventors: Hamid Ghavami Kia, Sheila Farrokhalaee Kia, Joseph C. Simmer, Terrence James Wathen, Mark A. Buffa
  • Patent number: 6695943
    Abstract: A hearing aid instrument of the in-the-ear type (and preferably CIC) provides a plate member with electronic hearing aid components mounted thereto. The plate member is preferably of a harder material such as hard plastic. A soft polymeric body is bonded to the plate member and encapsulates preferably a plurality of the electronic hearing aid components. The body is soft and is shaped to conform to the ear canal of the user. The soft polymeric body and encapsulated electronic hearing aid components define a soft structure compliant to the ear canal during use and that is substantially solid and free of void spaces between at least some of the components and the ear canal. This combination of soft compliant structure and encapsulated electronic hearing aid components addresses problems of peripheral leakage, poor fit, pivotal displacement that occurs with jaw motion and internal cross talk of components housed in prior art hollow type hearing aids.
    Type: Grant
    Filed: May 14, 2001
    Date of Patent: February 24, 2004
    Assignee: Softear Technologies, L.L.C.
    Inventors: Roger P. Juneau, Lynn P. Creel, Edward J. Desporte, Michael Major, Gregory R. Siegle, Kelly M. Kinler
  • Patent number: 6688073
    Abstract: A method of forming a composite panel with a facade comprising a planar arrangement of thin discrete facers on a body of structural backing material. The method comprises the steps of providing a horizontal casting bed, providing a plurality of facers each with chamfers at corners between side-rear and end-rear walls, arranging the facers in abutting relationship atop the casting bed and in a selected pattern in a face down planar configuration so that the chamfers on the facers open upwardly and define narrow elongated sealant channels at joints between contiguous facers. Depositing a sealant in the channels and pouring concrete as a structural backing material atop the facers, the rear surfaces of the facers and the concrete adhering to form a composite panel.
    Type: Grant
    Filed: January 29, 2002
    Date of Patent: February 10, 2004
    Assignee: Chameleon Cast Wall System LLC
    Inventors: Pieter Anthony VanderWerf, Ivan J. Becica, John Poignard, J. C. Henry, III, Jirair Youssefian
  • Patent number: 6663803
    Abstract: A metal mold is machined via a computer numerically controlled wire-cut electrical discharge technique so as to describe a fractally profiled parallel grooves-and-ridges configuration. Fibers are placed along the mold's grooves. Using the mold combined with the fibers situate in its grooves, a first composite portion is resin transfer molded so as as to describe a complementary fractally profiled parallel grooves-and-ridges configuration, and to include, in its ridges, the fibers situate in the mold's grooves. Fibers are placed along the first composite portion's grooves. Using the first composite portion combined with the fibers situate in its grooves, a second composite portion is resin transfer molded so as as to describe a complementary fractally profiled parallel grooves-and-ridges configuration, and to include, in its ridges, the fibers situate in the first composite portion's grooves, and to effect secondary bonding of the first and second composite portions.
    Type: Grant
    Filed: December 20, 2001
    Date of Patent: December 16, 2003
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: Karin L. Gipple, Dale G. Karr, Liming W. Salvino
  • Patent number: 6663820
    Abstract: A method for manufacturing microneedle structures is disclosed using soft lithography and photolithography, in which micromold structures made of a photoresist material or PDMS are created. The micromold manufacturing occurs quite quickly, using inexpensive materials and processes. Once the molds are available, using moldable materials such as polymers, microneedle arrays can be molded or embossed in relatively fast procedures. In some cases a sacrificial layer is provided between the forming micromold and its substrate layer, for ease of separation. The microneedles themselves can be solid projections, hollow “microtubes,” or shallow “microcups.” Electrodes can be formed on the microneedle arrays, including individual electrodes per hollow microtube.
    Type: Grant
    Filed: March 14, 2001
    Date of Patent: December 16, 2003
    Assignee: The Procter & Gamble Company
    Inventors: Francisco Arias, Faiz Feisal Sherman, Grover David Owens
  • Patent number: 6663812
    Abstract: The invention relates to a method and system for producing verified component designs and for assisting in tool design to near-production specification in the materials of choice, via production processes and in considerably shorter time scales than has previously been possible.
    Type: Grant
    Filed: July 24, 2000
    Date of Patent: December 16, 2003
    Inventor: Paul Anthony Shepheard
  • Patent number: 6644954
    Abstract: A pressure transmitter for use in the curing of composite components may take the form of a caul plate, pressure intensifier or vacuum bag and is formed from a curable elastomeric material which is partially cured, normally when supported on a mould, at a temperature not exceeding 100° C. It is subsequently further cured at, for example 175° C., while unsupported. It may incorporate a reinforcing layer formed from a curable resin pre-impregnated fibrous material.
    Type: Grant
    Filed: February 26, 2002
    Date of Patent: November 11, 2003
    Assignee: Advanced Composites Group Ltd.
    Inventor: Roger Mark Sloman
  • Publication number: 20030205840
    Abstract: This invention is a method for making purses and other bags. The first part of the process is forming a female mold of the bag. This mold can be formed in extreme detail. The mold is then preheated and colored plastic is then poured into it. The mold is then lowered into a hot oil or salt bath and the plastic and the hot oil or salt reacts causing the plastic to line the interior wall of the mold. The mold is then taken out of the hot oil or salt bath and placed in a cooling tank where the plastic is cooled and sets. The mold is taken out of the cooling tank and the unfinished bag is removed from the mold. The bag is then finished by polishing and adding any accessories such as snaps, zippers, linings, and handles to the bag. The process can be used to form a hard or soft sided bag.
    Type: Application
    Filed: May 1, 2002
    Publication date: November 6, 2003
    Inventors: Gail Elaine Hottenroth, Craig James Castro
  • Patent number: 6638460
    Abstract: A method for preparing a mold form includes forming a mold blank having a surface corresponding to the surface of the article desired and enclosing the mold blank in an open ended enclosure. A thin layer of polymer resin, preferably polyurea is sprayed on the surface of the mold blank and allowed to cure. Heat transfer tubing is inserted over the resin layer. A mixture of metallic pellets and epoxy are inserted over the heat transfer tubing and then another layer of resin is sprayed over the mixture. After the resin has cured, the mold blank is removed to expose the mold form having an outer surface of polyurea.
    Type: Grant
    Filed: December 15, 1998
    Date of Patent: October 28, 2003
    Inventor: David M. Wahl
  • Patent number: 6610230
    Abstract: A method of making a mold directly from the object to be molded is disclosed. The object is placed within a walled enclosure having a closed bottom and open top. A plurality of elongated metal rod elements is vertically introduced and packed into the enclosure in vertical contact with said object and side by side contact with one another. An infiltration agent, such as a liquid resin or metal, is introduced over the elongated metal rod elements and allow to permeate into the spaces between the rod elements. The mass consisting of the liquid infiltration agent and the elongated metal elements is allowed to solidify into a mold which is removed from the object.
    Type: Grant
    Filed: September 18, 2001
    Date of Patent: August 26, 2003
    Assignee: National Research Council of Canada
    Inventors: Jiaren Jiang, Xing Yang Liu, Millan Yeung
  • Publication number: 20030155684
    Abstract: The present invention relates to the use of C2-C24 aliphatic diols, preferably 1,2 propane diol as a thixotropic enhancing diluent in moisture curable organosiloxane compositions, especially in the presence of silicone-polyether block copolymer thixotropes and to the application of these compositions on vertical substrates.
    Type: Application
    Filed: February 11, 2003
    Publication date: August 21, 2003
    Inventors: Steven Eric Heilman, Brian Patrick Bayly
  • Patent number: 6607683
    Abstract: A method is described comprising the steps of modifying a natural article to a predetermined configuration, making a mold of at least part of the modified natural article, filling the mold with a castable material to produce a reproduction of at least part of the surface of the modified natural article, modifying the reproduction to a predetermined configuration, making another mold from the modified reproduction and filling this mold with a castable material to produce another reproduction of at least part of the surface of the modified natural article; the second mold can be used to produce reproductions in commercial quantities.
    Type: Grant
    Filed: September 4, 1998
    Date of Patent: August 19, 2003
    Inventor: Bruce E. Harrington
  • Patent number: 6602452
    Abstract: A system and method for molding the shell of a medical device or other molded article is provided. The system includes a multi-axis rotational molding machine in which a mold is mounted. The mold has a cavity in the shape of the article to be molded. The mold seals to hold a vacuum. In operation, silicone or other molding material is inserted into the mold, vacuum is applied to the mold, the mold is rotated about at least two axes and a molding material coats the inside walls of the mold to form the shell or other desired article. A rotationally molded medical article is also provided.
    Type: Grant
    Filed: July 18, 2001
    Date of Patent: August 5, 2003
    Assignee: McGhan Medical Corporation
    Inventor: David J. Schuessler
  • Patent number: 6599452
    Abstract: A method is provided for manufacturing molded simulated stone and wood architectural articles for buildings and homes. The method incorporates a unique mold assembly including a resilient silicone rubber mold supported within a rigid mold cradle/foundation, and a vented lid having a High-Density Polyethylene (HDPE) interior surface. The silicone rubber mold is initially treated with a liquid polyester gel coating that is cured and then coated with an acrylic/vinyl ester back coating. Once the back coating is cured, a predetermined volume of a modified high-density, natural mineral fiber-reinforced, 2-component hybrid polyurethane liquid expanding composition is dispensed therein and the mold is covered with the vented lid. The system is pressurized and heated to produce a molecularly-fused, lightweight rigid article having the desired architectural shape.
    Type: Grant
    Filed: June 17, 2002
    Date of Patent: July 29, 2003
    Assignee: Bevona, Inc.
    Inventor: Samuel J. Ferguson
  • Patent number: 6558496
    Abstract: There is disclosed a method for simulating the appearance of an article having surface texture comprising the step of applying a textured skin having a surface texture to a prototype to produce a textured prototype, thereby to simulate the appearance of the article having surface texture.
    Type: Grant
    Filed: January 11, 2000
    Date of Patent: May 6, 2003
    Assignee: Eschmann-Stahl GmbH & Co., KG
    Inventors: Nigel Brooke, Michael Stuart Miller
  • Publication number: 20030038396
    Abstract: A resin (61) as a material of a resin mold is injected in a second resin filling space (57) from a resin injection hole (51) provided in a second back surface reinforcing member (50). When the resin overflows from a resin overflow hole (52), the injection of the resin is stopped, followed by curing of the resin. During the operation of the resin filling step, since a downward load equivalent to a total of a weight of the resin injected in the second resin filling space and the injection pressure is applied to the master model (30), there is a possibility that the master model be deflected downwardly; however, in actual, since the back surface of the master model is overall supported by the temporary filler (59), the master model is not deflected downwardly.
    Type: Application
    Filed: August 22, 2002
    Publication date: February 27, 2003
    Applicant: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Hiroshi Shirakawa, Isao Nishigaki, Masumi Kunii
  • Patent number: 6521157
    Abstract: A press forming die is fabricated by initially fabricating a die forming panel, by press forming, which provides a die surface for the press forming die. During fabricating the die forming panel, a shaped panel is obtained by initially press forming a first blank material with a die forming prototype and a punch forming prototype. Next, the shaped panel is mounted onto the punch forming prototype again and, thereafter, a die forming panel is obtained by press forming a second blank material. The die forming panel is then mounted on a frame body and a backup material is formed between a space between the frame body and the die forming panel, thereby fabricating the press forming die. Since the die surface of the press forming die can be shaped by press forming, the press forming die can be simply fabricated.
    Type: Grant
    Filed: December 19, 2000
    Date of Patent: February 18, 2003
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Teiji Watanabe, Masafumi Nakamura, Yoshikazu Nakamura
  • Patent number: 6516866
    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.
    Type: Grant
    Filed: August 12, 1999
    Date of Patent: February 11, 2003
    Assignee: Fastcore LLC
    Inventor: Kirk Jones
  • Patent number: 6497834
    Abstract: Changing the contour of a recess (12) in a body of solid material to a revised contour wherein a pattern (24) is made having the revised contour and this pattern is placed in the recess with a curable plastic material (31). After the curable plastic material is hardened, the pattern is removed providing the revised contour (30) of the recess. The body of solid material can be a flow channel block.
    Type: Grant
    Filed: January 15, 2001
    Date of Patent: December 24, 2002
    Assignee: The Goodyear Tire & Rubber Co.
    Inventors: Richard David Vargo, Gary Robert Burg
  • Patent number: 6489418
    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.
    Type: Grant
    Filed: April 2, 1996
    Date of Patent: December 3, 2002
    Inventor: Klaus Mosbach