Abstract: The present invention relates to spraying of high viscosity silicone molding compositions and to cured silicone molds or tools formed by that process that allow for near perfect transfer of detail from a surface to a molded object.

Abstract: A method for molding experimental, prototype and replacement parts from rubber-like materials using a frangible core wherein a core is made by coating a cavity with a mold release agent, coating the release agent with a quick set resin, pouring a two-part polyurethane resin into the cavity, sealing the cavity and allowing the polyurethane to foam, expand and adhere to the quick set resin.

Abstract: Tooling for use in forming articles and a method for making same wherein the tooling includes a mold. The mold has a mold surface having an interior and an exterior. A plurality of metallic strands are positioned adjacent to the interior of the mold surface. The mold further includes at least one metallic heat transfer tube for containing a fluid cooling agent. One or more heat transfer rods can also be positioned in the mold. A layer of a plastic material is placed adjacent the interior of the mold surface. The plastic material surrounds the metallic strands and the metallic heat transfer tubes and rods. When heat is produced on the mold during a molding operation, the heat is transferred through the metallic strands and the heat exchange tubes and rods. The heat is dissipated by the cooling affect caused by the cooling fluid in the tubes.

Abstract: Methods for manufacturing texturized coverings for implants into the human body are described which generate small wells or channels on the exterior surface of the implant. Optionally, the texturized surface may be formed by affixing globules on the exterior surface of a mandrel or the interior surface of a mold, which is then coated with silicone rubber and cured. The surface may be optionally microtexturized, for example, by microtexturizing the surface of the globules by etching or sand blasting.

Abstract: An improved electrical insulator for high voltage transmission lines is formed from certain polymer-based concrete compositions. An apparatus provides for the molding of the polymer-based mixture to form a highly degassed product. The method and apparatus include the ability to combine the constituents of the mixture in a mixer. A vacuum is applied to the mixture to degas the mixture. A mold is filled with the degassed mixture without introducing air thereinto in the absence of a vacuum. The resulting insulator has highly reduced air entrainment.

Abstract: A sign having a raised message-defining image which may be read by sighted individuals and a series of raised dots presenting a corresponding encoded message in Braille characters, wherein the visually observable message is flat and has relatively sharp outlines so that it can be readily seen, whereas the Braille characters are of dome shaped configuration that fully comply with Braille specifications. A visually impaired person may touch and decipher the Braille characters and also feel the relatively sharp outline of the message intended for visual observation in order verify the content of the dual medium message of the sign.

Abstract: The present invention relates to spraying of high viscosity silicone molding compositions and to cured silicone molds or tools formed by that process that allow for near perfect transfer of detail from a surface to a molded object.

Abstract: A method of continuously forming an integrally molded structure in a multiaxis rotational molding operation including the steps of rotating a multimold section mold assembly about at least three axes. A first freshly formed polymerizable mixture is flowed over surfaces of an enclosed mold cavity within the multisection assembly. Flowing of the first mixture over the cavity surfaces and formation of a first resin therefrom is monitored through optical fibers extending through the mold sections. Second and third freshly formed polymerizable mixtures are flowed over resin formed within the mold cavity. Flowing of the second and third mixtures and formation of resins therefrom are monitored through optical fibers extending through the mold sections. The rotation of the multisection mold assembly is continued throughout the modling operation. Each axis rotation of the multisection mold assembly is monitored individually.

Abstract: A method of making a ceramic burner head includes the steps of forming a positive mold that conforms to the shape of a burner head and providing a partition plate to the positive mold; forming a negative plaster mold by the use of the positive mold; introducing a ceramic slurry into a mold cavity of the negative mold; causing the ceramic slurry in contact with a surrounding wall that confines the mold cavity of the negative plaster mold to possess a layer of dried ceramic with a predetermined thickness, and to further possess a hollow portion that is confined by the layer of dried ceramic and that is filled with a non-dried ceramic; removing the negative plaster mold and providing the layer of dried ceramic with burner holes; and sintering the layer of dried ceramic to form the ceramic burner head.

Abstract: The method of fabricating a complex part made of composite material and having a plurality of panels oriented in diverse angular relationship, and utilizing a plurality of conformable cauls upon which the composite material is individually laid up and which cauls cooperate to form one of the molds used in the co-curing of the individually laid-up composite materials.

Abstract: A method for preparing a microporous ink-impregnated marking structure according to the invention involves use of a window-like frame instead of a conventional chase. The frame is placed on the upper face of the matrix board or mold so that the premix, containing ink, plasticizer and resin, is retained therein. The premix fills the cavities and excess premix forms a continuous layer over the cavities in the mold, with the edges of the layer retained by the frame. A layer of an ink-absorbent backing material is placed on the layer of premix, and the backing is covered with a plate. The assembly is heated with pressure to form a microporous, marking fluid impregnated structure having a relief pattern corresponding to the cavities, and then cooled. The marking structure can then be used to make self-inking hand stamps.

Abstract: A molded strap channel and method are disclosed for a kayak and the like or article molded from a flexible skin using a rotational molding process. The strap channel includes a continuous channel having an arcuate shape and a continuous taper from a first channel opening to a second channel opening. First and second channel openings open in a common surface of the flexible skin of the hull and lie generally in a common plane. In accordance with the method, a rotational molding process is disclosed wherein plastic material in a split mold is subjected to a rotational molding process which forms a thin, plastic hull and a continuous strap channel molded about a forming member attached to one-half of the mold. The forming member is unattached from the mold, and the hull is removed from the mold whereby the forming member is tapped and removed from the strap channel so that a continuous strap channel is molded as one-piece with the hull having first and second channel openings as described above.

Abstract: An object retention form liner is described for use in holding and transferring objects, such as thin bricks to the finished surface of concrete structures. The form liner is produced by strategically positioning a plurality of bricks in a face-up position in a flat, shallow mold. Recesses sized to fit the bricks can be provided in the surface of the mold with a sealing ridge provided between each of the recesses. The bricks are positioned in the recesses and a liquid elastomeric material is poured into the mold to cover the bricks. Reinforcing fiberglass mesh can be embedded in the elastomeric material to provide additional tensile strength to the liner. Upon setting, the liner and retained bricks are removed from the mold and the liner can be stored, shipped or used in concrete construction. The liners are attached to the inside surface of concrete forms and the bricks are held rigidly in place while the concrete is poured and sets.

Abstract: Methods for applying coverings to surfaces by casting at least a portion of the covering in a mould from a solidifiable liquid mix. The mould may be applied directly to the surface or to an already cast layer of the covering. In another embodiment an outer portion of the covering is cast in a mould and is affixed to the surface, or to an already cast layer of the covering, so as to define a void between the outer portion and the surface or already cast layer. The void is filled with solidifiable liquid mix.

Abstract: An embossing roll is formed by a process which includes molding a seamless embossing roll within a seamless sleeve. The sleeve has indicia disposed about the inner circumference and which is then reverse molded into the roll.

Abstract: My invention relates to the art of making three dimensional impressions and likenesses. More specifically, my invention is an improvement of making three dimensional duplicate of a persons facial appearance and expression.

Abstract: The invention provides a method of making an elastomeric mandrel for use in formation of parts from composite materials. The method of making includes providing a separable mold with an interior chamber shaped to provide a desired exterior mandrel size and shape; applying uncured elastomeric material to surfaces of the interior chamber of separated parts of the mold; joining the elastomeric material by assembling the mold parts prior to cure such that the material joins at seams and allowing the elastomeric material to cure into a shape of the desired flexible mandrel. The mandrel is provided with a fill opening such that it is fillable with a particulate solid media and evacuable to compact the media.

Abstract: Injection molds suitable for use in injection molding, structural foam molding, low-pressure injection molding, and gas-assisted injection molding of plastic articles are described. The injection molds contain a thin metal layer contoured on its outer surface to the shape of the article to be molded, a rigid thermoset plastic material cast upon the inner surface of the metal layer and supporting the metal layer, and heat transfer elements cast within the plastic material and located adjacent to the metal layer to transfer heat for the metal layer and the plastic material. Preferably the thin metal layer is nickel, the plastic material is epoxy, and the heat transfer elements are metal chips and heat transfer tubing. The injection molds of the present invention can be prepared at considerable cost and time savings relative to conventional injection molds.

Abstract: A method of manufacturing a precision micro-filter and a micro-filter manufactured thereby is disclosed. A micro-mold is manufactured using micro-machining technology (such as micro-electrical-discharge machining technology, laser-beam micro-machining, electron beam micro-machining) to make a filter mold with a plurality of rod-like protrusions, of the shape, dimensions, and spacing required for the pores of a finished micro-filter. A molding material is placed into the micro-mold, the molding composition is allowed to solidify to form a micro-filter, the passageways of which conform precisely to the rod-like protrusions of the mold. This micro-filter is then separated from the micro-mold.

Abstract: The present invention is a method of producing perforated articles. A woven material, such as woven graphite, is impregnated with a curable high flow resin, such as epoxy or BMI resin, and placed on a pressure transmitting pad which has stud holes positioned and sized so as to permit the studs of a flexible mold to fit therein. The material can be smoothed over the pad using a roller. The studded flexible mold, which can be of polypropylene, polyethylene or PEEK, is then applied, pushing the studs through the woven material and into the stud holes. The pressure transmitting pad is removed and the flexible mold with the woven material thereon is formed to a desired contour, such as through placing the mold on a forming tool, followed by partially curing the resin impregnated in the woven material until the impregnated resin material has sufficient structural integrity to permit removal from the mold without permanent deformation.

Abstract: A casting method for manufacturing various types of ceramics products having an intricate configuration and a partly diversified wall thickness, such as compressor scroll blade and a screw rotor, by casting a slurry including ceramics, etc. in a mold, includes an arrangement wherein the mold is partly or entirely formed of a flexible gel material which can be melted by heating at a temperature lower than the boiling point of the dispersion medium, whereby the stresses generated when molding the product can be mitigated. Thus, the molding of a product having a high level of dimensional accuracy can be carried out with ease.

Abstract: A process for forming an artificial rock is provided. The process includes forming an outer mold having an outer surface and inner surface, the inner surface defining the size, shape and detail of the artificial rock to be formed. An inner mold is formed to be receivable within the outer mold. The inner mold and outer mold are secured in place relative to each other to define a space therebetween. Molding material is poured into the space between the inner mold and outer mold. The molding material is allowed to harden to form an artificial rock within the space. The molds are then separated leaving the artificial rock.

Abstract: An improved method for the repair of fiberglass boat hulls by replicating surface textures on the boat hulls is disclosed. A laminar, dimensionally stable, flexible mold is formed having a negative impression of the surface texture to be replicated formed on one side thereof. The laminar, dimensionally stable, flexible mold then is placed atop a recipient boat hull surface and a layer of fluid casting material. Pressure is applied to the laminar, dimensionally stable, flexible mold to expel entrapped gas from the fluid casting material and to evenly distribute the flexible casting material over the recipient hull surface. The fluid casting material is cured, and the laminar, dimensionally stable, flexible mold is removed. A replica of the surface texture remains on the recipient boat hull surface.

Abstract: A mold forming method includes steps of preparing a master having pores corresponding to an original image, holding the master under a predetermined tension, applying a mold forming material to the master, and hardening the mold forming material to produce a mold having an image corresponding to the original.

Abstract: The invention describes a method for making monolithic castings of transparent silica aerogel with densities in the range from 0.001 g/cm.sup.3 to 0.6 g/cm.sup.3. Various shapes of aerogels are cast in flexible polymer molds which facilitate removal and eliminate irregular surfaces. Mold dimensions are preselected to account for shrinkage of alcogel which occurs during the drying step of supercritical extraction of solvent.

Abstract: A vacuum molding process uses a flexible molding skin having an imprint face arranged inside an airtight compartment. Before the vacuum is made, a pasty plastic material is incorporated in the compartment facing the imprint The vacuum is then made in the compartment to press the flexible molding skin onto the plastic material with formation of a molded surface with sculptures and asperities giving a decorative or functional granular appearance. The molding skin is made of a flexible anti-adhesive organic material, notably silicone, for ease of removal from the mold after the plastic material has hardened Shaping of the panel is performed after the vacuum bag has been positioned on a shaping part. The process is used for manufacturing artificial climbing wall panels.

Abstract: A method for forming a mold for encapsulating glass sheets with a gasket which includes the steps of positioning a rigid member 18 having a finishing surface 19 and a seal 30 adjacent a model 2, forming a first mold section 10 about the rigid member 18, the seal 30, and the model 2 and adjacent the first side of the model 2, forming a second mold section 12 adjacent a second side of the model 2, and then separating the first mold section 10 and the second mold section 12 and removing the model 2. In one embodiment of the invention, the rigid member 18 is prepared by forming an initial member 24 corresponding at least in part to the shape of the model 2, using the initial member 24 to prepare a cast, casting the rigid member 18 in the cast, and then preparing a finishing surface 19 of the rigid member 18.

Abstract: The present invention is a contoured wall and method 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 interlocking wall portions that each have at least two non-linear mating surfaces. Each of the wall portions further has a lateral face contoured to resemble the stone wall. The wall is formed from hardenable construction material such as concrete poured between two mold members. Each of the mold members has a lateral mold face with at least one of the lateral faces having a plurality of interlocking contoured relief portions to provide a molded surface having the contour of a stone wall. In one embodiment, at least one of the mold members includes a plurality of individual form liners, or mold modules, each of which includes two non-linear mating edges and a lateral relief mold face.

Abstract: The present invention is a contoured wall and method 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 ar positionable in a plurality of arrangements wherein the interlocking portions and recessed portions along the mating edge of each form liner mate along the mating edge of the adjacent form liner to form a continuous lateral relief mold face.

Abstract: A method of making a mold assembly for molding inner and outer shells of an equipment shelter utilizes a generally rectangular frame on which are supported a plurality of large flat panels formed of plywood and covered by thin sheets of stainless steel. The panels are separated by rib gaps on the sides and corner gaps at the corners which are closed by temporary, wooden rib and corner patterns. A reinforced plastic laminate is applied to the temporary patterns to form negative molds. When cured, the negative molds are removed from the frame, along with the temporary patterns. A reinforced plastic laminate is applied to each of the negative molds and cured to form permanent rib and corner molds. The permanent molds are positioned in their respective rib and corner gaps to complete the mold assembly.

Abstract: The present invention is directed to a method of constructing a tool for forming an impression in a surface of a moldable material. The method includes the steps of: providing a mold for forming a tool, the mold including a pattern forming element for forming a pattern in a surface of the tool, and dispensing a first layer of flowable material into the mold. The first layer includes upper and lower surfaces and a predetermined pattern is formed in the lower surface of the first layer. The first layer is substantially hardened and a handle is positioned on the upper surface of the first layer. A second layer of flowable material is dispensed into the mold to cover at least substantially the entire surface of the first layer subsequent to hardening of the first layer, and the second layer is substantially hardened.

Abstract: A rigid, durable construction material is described along with a method for making the material. The material is particularly characterized by having a specific, textured surface which can resemble stucco and which can be reproduced exactly any desired number of times. The unique surface charactistics of the invention are obtained by preparing a reusable mold which is obtained by a reverse casting of a polymeric gel onto a cellular foam surface. The construction material of the invention is essentially a laminated, rigid backing having a polymeric surface with the desired texture obtained by casting onto the reusable mold.

Abstract: A process for preparing cast articles includes preparing a primary mold of a flexible resilient bag-shaped membrane, disposing casting material in a flowable state into the primary mold and allowing the casting material to harden. Optionally, a relatively fixed secondary mold or a combination of relatively fixed secondary molds can be used adjacent the outside of the primary mold to impart a predetermined shape to portions of the cast object. A continuous ultra-smooth surface is created on the cast objects duplicating the surface of smooth naturally weathered stone.

Abstract: The invention provides a composition and a method for studying skin surface areas with simplified magnifying devices by making a replication of the skin surface area while minimizing irritation to the subject's skin, cracking of the replicas, surface artifacts, and air bubbles in the replicas. The method entails preparing a negative skin surface replica composition by mixing a silicone polysiloxane base and a biocompatible surface tension modifying agent. The mixture is placed in a vacuum desiccator to remove air bubbles and thereafter a curing agent is added to the mixture. An adhesive collar is placed on the subject's skin, which collar surrounds the surface area to be replicated, and thereafter the composition is applied to the skin surface area and the adhesive collar and allowed to dry. The negative skin surface casting is removed from the skin area and is then placed skin side up in a mold cup.

Abstract: A method of making a mold for use in the manufacturing of appliances for use in filling endodontically prepared root canals including the steps of drilling spaced apart holes into a flat base member, inserting into each of the holes elongated metal patterns having the desired configuration of a filler covered carrier shaft portion of an endodontic appliance, forming a vessel with the base member as the bottom and the patterns extending upwardly therein, pouring liquid plastic and a catalyst into the vessel and allowing it to solidify to form a mold, and removing the mold from the vessel and from the base, the mold having a cavity therein for each of the patterns, each cavity being useful for forming an appliance for use in filling an endodontically prepared root canal.

Abstract: Compound concrete composition for the manufacture of moulds, comprising: (1) a binder which comprises an alkaline-earth mineral substance, a constituent made up of fine particles of a compound other than an oxide, 90% of which have a particle size of between 1 and 150 .mu.m with a median diameter of between 3 and 20 .mu.m, these fine particles comprising particles of a substance which has a thermal conductivity higher than approximately 30 W/mK, chosen from silicon carbides, silicon carbonitrides, silicon nitrides, boron carbides, titanium carbides and tungsten carbides and a constituent made up of ultrafine particles at least 70% of which have a particle size smaller than 1 .mu.m with a median diameter of between 0.3 and 0.8 .mu.m, (2) water optionally with the addition of a dispersant, and (3) fillers comprising metal granulates and metal fibres, wherein the water/binder ratio is lower than 0.20 and the concrete composition has a thermal conductivity at 200.degree. C.

Abstract: In a process for covering an object by means of at least one flexible piece, a fluidized bed of particles (8) is covered by a flexible cloth (10), the flexible covering piece (12) is placed above said cloth, the object (13, 14) is placed above said cloth, pressure is applied to said object, deforming the flexible sheet and immersing the object in the fluidized bed until a mating imprint is formed in the latter. The covering can be effected by gluing, in particular with a previously applied heat-activated adhesive in which case the fluidized bed is obtained by means of a current of hot air at a temperature above the activation temperature of the adhesive. The process is particularly suitable for assembling and mounting seat covers. Also described is a device for implementing the process.

Abstract: A slip casting mold suitable to be used for the production of a hollow ceramic article for insert casting can be easily produced by a method wherein granules having an average grain size of at least 30 .mu.m are adhered to the surface of a mold to produce a mold having a 10 point average surface roughness R.sub.z of at least 30 .mu.m, and the resulting mold is used in the production of the slip casting mold.

Abstract: A method of making a femoral rasp wherein the hip stem implant is used to make a two part mold. The mold halves are separated and the implant removed to yield left and right mold halves representing corresponding halves of the hip stem. The cavities of the mold halves are lined with wax and a plurality of blades are imbedded into the wax such that an anchor portion of each of the blades remains exposed. The mold halves are connected together and a stem of handle is inserted therein. A moldable material such as PMMA is poured into the mold and allowed to cure. When the PMMA is hard or cured, the mold halves are separated and the wax is removed from the rasp body exposing the cutting surfaces of the teeth.

Abstract: In the manufacture of a wax pattern for use in the lost wax casting of a bladed rotor of the radial flow type, the bladed region of a master pattern is enclosed by a curable epoxy resin/aluminium powder composition. Sufficient of the cured resin composition is then machined away so that a plurality of resin composition segments are defined, one segment being interposed between adjacent blades on the master pattern. The segments are then removed from the master pattern and placed in an appropriately configured die member so as to define a complete die for the production of a wax pattern in the form of the master pattern.

Abstract: A new process for producing a reproduction of a painting or the like wherein the reproduction has a relief surface which imitates the relief surface of the painting or the like. Heat and pressure are applied simultaneously to an assembly consisting of a mold of the painting, a colored sheet for coloring the reproduction and a substrate to retain the reproduction. Subsequent to this step, shock cooling is applied. The reproduction thus produced does not suffer from the rebound effect of the prior art and good color integrity is maintained.

Abstract: A formwork for a draft tube which includes ganged precast forms, each precast form corresponding to a curved segment of the draft tube. The precast forms are molded with continuous side plates extending thereabout and anchored in the precast concrete form and projecting beyond the surface opposite to the contact surface to provide a flange. A fastening means for attaching adjacent forms with a space therebetween to allow for stripping. A method includes determining the outline of the inner surface of the draft tube and dividing it into segments and preparing molds to make precast forms corresponding to each segment. The precast forms are assembled and shored to provide the draft tube ganged formwork, and concrete is poured about the draft tube formwork and is cured. The precast forms are stripped from the set concrete structure and reused in another draft tube formwork.

Abstract: A pinstripe painting guide is fabricated by attaching a magnetic flexible guide rail to a hollow flexible support member by mating a channel to a T-shaped male mating member. This assembly is then attached to a surface to be painted and adjusted to provide an appropriate contour. The ends of the hollow support member are then plugged and the hollow support member is then flooded with a hardenable liquid such as fiberglass resin. When the liquid cures, the resulting tool is rigid and can be used for repeated application of similar pinstripes to the same type of surface. This process, for example, can be used to produce such a guide assembly for a particular model of automobile.

Abstract: A plunger (10) for supporting a wall (46) of e.g. a refrigerator door against deformation from an expanding, and hardening foamed plastic (52) on the other side of the wall. An evacuated bag-formed part (18) filled with a particulate material (20), has a surface (42) showing an impression of the form of the wall (46). The plunger (10) is reshapable, so that it can serve as a plunger for walls (46) of different forms.

Abstract: A method for making a compact for a densified cutting insert, an easily machinable material is cut to the desired form, a plastic molding material having specific properties is contacted with the shaped machinable material, hardened to form a mold, and the resulting mold is used to form a compact for a cutting insert having the desired configuration which compact may be subsequently densified.

Abstract: A technique for forming a mold to replicate large numbers of plastic articles, such as by injection or blow molding, wherein the mold contains a hologram or other microstructure for transfer to an outside surface of the molded article. The mold is made by electrodepositing a metal on a model of the article to be molded. Before this deposition, the hologram or other microstructure is formed on a surface area of the model by any one of several techniques. The result is a unitary mold piece in the shape of the article and having the hologram or other microstructure integrally formed on its inside surface.

Abstract: A rigid, durable construction material is described along with a method for making the material. The material is particularly characterized by having a specific, textured surface which can resemble stucco and which can be reproduced exactly any desired number of times. The unique surface characteristics of the invention are obtained by preparing a reusable mold which is obtained by a reverse casting of a polymeric gel onto a cellular foam surface. The construction material of the invention is essentially a laminated, rigid backing having a polymeric surface coating with the desired texture obtained by casting a polymeric gel onto the reusable mold.

Abstract: A method for determining the degree of adherence to a non-flat, opaque vehicle panel surface of a component adhered thereto. The method includes providing an integrally cast clear matched surface in the panel so that the contacting surfaces of the component may be directly viewed.

Abstract: A method of forming a three-dimensional composite structure. Uncured portions of the composite structure are first assembled between a initially rigid heat-softening inner layer of ABS plastic and a hard outer mold surface. Prior to curing of the composite structure, pressure and heat is applied to the ABS layer to soften the layer. Thereafter, pressure is applied to the side of the ABS layer opposite from the composite structure, thereby to compact the uncured portions of the composite structure against the hard outer mold. Stiffening beams may be incorporated into the composite structure, so as to yield a lightweight, strong composite structure that can be used as a pressure vessel in an aerospace vehicle.

Abstract: A method of manufacturing and using a resinous concrete in the production of forming tools for stamping, trimming and other treatments of sheet metal parts. The process includes first mixing at least one resin and hardening agent and then adding a siliceous pulverulent grain filler so that the gravimetric ratio between the resin and hardening agent and the filler when mixed for a time depending on the working temperature at a work site will result in a mixture of filler grains and resin essentially free of macromolecules and having remaining spaces between the grains filled with the essentially macromolecular free resin thereby eliminating the formation of bending bridges. The final mixture is then poured into a casing containing working parts and moulding elements to create forming tools useable after the mixture polymerizes.