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 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 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.

Abstract: An acoustically sealed earmold for a hearing aid insertable into the ear of individuals with impaired hearing can be prepared in situ employing the hydrophilic composite polymer materials described herein. Such composite materials include at least one hydrophilic polymer in a powder form and one or more liquid components of which at least one is hydrophilic and which can be polymerized with said hydrophilic polymer. The resulting earmold has a shape-retaining, non-tacky flexible consistency which allows it to be shaped further and also to be modified to accommodate a receiver adapter or external receiver. The earmold can then be cured by any of the conventional curing methods to retain its shape permanently. This method enables an audiologist to fit the earmold and evaluate the hearing aid in a single office visit.

Abstract: A method for the production of stopcocks for medical devices including a plug and a housing made of plastic. First one of the two parts (1 or 9) is injected and afterwards the other part (9 or 1) is injected into or around the already manufactured part (1 or 9).

Abstract: A method of making a window pane that has a plurality of glass pieces arranged in a predetermined pattern and joined at adjacent edges by cames having flanges on both faces of the pane. The method includes the steps of making a mold of both faces of a master window to be duplicated, positioning pieces of glass which are copies of these used to make the original onto the molded surface of one mold with the edges of each piece of glass adjoining the open channel pattern of the mold, said pattern produced by the cames of the master window. The faces of the mold portions are joined, clamping the glass pieces between them. Moldable, colored resin is introduced to fill the spaces between the glass pieces and allowed to set. The finished article is then removed from the mold and has cames which faithfully duplicate in pattern, color and texture the leaded cames of the original.

Abstract: A method of making a high load tool having a hard body of plastic material with compression plates on opposites sides to compress and strengthen the body. The method includes the steps of inserting passage forming pipes into a container and retaining the passage forming pipes in predetermined locations. Epoxy resin is poured into the container to cover the passage forming pipes and then the epoxy resin is cured. Elongated rods are inserted into the passage forming pipes and a pair of load spreader plates are placed at opposite ends of the elongated rods. Threaded bolts are advanced on at least one end of the elongated rods to move the spreader means towards one another and to compressively load the body.

Abstract: The method of making a plastic article having a plurality of small openings which utilizes a plurality of thin plastic tubular members combined together in a side-by-side relationship forming an assemblage. Each tubular member has an exterior layer of a first plastic and a core of a second plastic. The second plastic is to be dissolvable by a solvent. This assemblage is passed through a furnace with the result that the assemblage is drawn into a thin filament. Once cooled, the thin filament is cut into segments of a desired length and these segments are placed within a solvent bath for a sufficient period of time in order to affect complete removal of the second type of plastic resulting in producing of a plurality of small, through openings within each section.

Abstract: A method for molding powders to form a shaped compact comprising the steps offorming a thin-wall resilient mold having an outer surface and having at least one opening adjacent a surface of a model of a desired shape, forming a mold support on the outer surface of the thin-wall resilient mold, so that the mold support adheres to the outer surface of the thin-walled resilient mold,removing the model from the thin-wall resilient mold whereby a cavity is formed in a portion of the thin-wall resilient mold, from which the model is removed, filling up the cavity of the thin-wall resilient mold with a powder as a forming material through the opening,sealing the opening of the thin-wall resilient mold after having evacuated air from the inside of the thin-wall resilient mold,removing the mold support from the thin-wall resilient mold,subjecting the thin-wall resilient mold filled with the powder to a cold isostatic press.

Abstract: A process for making a model skin surface for testing adhesion of medical adhesive as a screening test and/or as an alternative to costly and highly variable human skin substrates including casting silicone rubber on human skin to produce a mold having human skin topography and pouring a water-swellable, water-soluble proteinaceous material along with a crosslinking agent and fatty acid constituent into the mold. The proteinaceous material crosslinks while in the mold and the water content of the material is adjustable to simulate varying moisture contents in human skin.

Abstract: A mould for an injection moulding apparatus, the mould including at least two mould parts which mate to form the mould cavity and which separate to permit removal of the moulded article, each mould part including a relatively rigid body having an abutment face which abuts with an abutment face of the other mould part when said parts mate, the body of at least one mould part including a recess in its abutment face which is filled with a resilient material defining a portion of said mould cavity.

Abstract: A method for rotational molding a thermoplastic article using a mold made of a fiber reinforced thermoset resin which has a heat distortion point above the melting point of the thermoplastic material. Metal or other materials may be used to provide different coefficients of heat transfer at preselected portions of the mold. The entire mold may include a thermal coefficient modifier to increase the heat transfer rate of the mold uniformly over the entire mold in addition to the preselected portions.

Abstract: A mold for forming a synthetic resin tray to be used in molding chocolate bars comprises a female mold portion defining a mold cavity and a male mold portion including a skirt projecting into the cavity. A plate is disposed in the male mold portion and engages an inwardly extending lip at the free end of the skirt. The plate is provided on a side facing the mold cavity with an inscription and is pressed against the lip by a pressure block disposed in the male mold portion. The pressure block is shiftable to enable a substitution of another inscription plate. The inscription plate may be provided with a projection on the inscription side for forming an opening or a recess in the injection molded tray.

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: Disclosed is an improved process for casting the impression of a tire tread by preparing a negative mold of the tire tread and making a positive cast from the negative mold. The improvement consists of pouring a liquid photopolymerizable composition into the negative mold of the tire tread, applying a vacuum, exposing the composition to ultraviolet radiation to cross-link the polymer, removing the positive cast from the negative mold, and exposing the cast to additional ultraviolet radiation in the absence of oxygen to harden the surface of the cast.

Abstract: An extrusion die useful for forming helical extrudate particles of inorganic oxide materials, is made by molding the die around pins having helical outer surface to form extrusion holes in the die. Helical walls of the extrusion holes are formed by the helical shape of the pins. When the molded die is formed, the helical pins are unscrewed out of the helical holes in the die to avoid damage to the die.

Abstract: A method of manufacturing components such as optical components (17, 18, 21, FIG. 2C) by means of a matrix which comprises a preform 12 of glass or quartz and has a skin 14 of a cured epoxy synthetic resin, the surface of which is the negative of a metal mold from which the matrix is produced. The matrix is suitable for use in the above-mentioned method, whereby optical components are produced which have surfaces that are for example, the aspherical negatives of the matrix surface.

Abstract: A method for making plastic tooling by forming a surface coat over a model of the article to be made. While still in a tacky condition, the surface coat is sprinkled with sand. After the surface coat is cured and has adhered to the sprinkled sand, the surface coat is wet with a laminating resin. Then a sand and epoxy mixture is poured into the core box to form the tool. Another version of the method includes the steps of disposing a vacuum tube into the sand-epoxy core and closing off the open side of the core box through which the core mix was tamped. The surface coat is applied around the model so that the cavity in the finished core is suitable for vacuum-forming an object without forming the conventional vacuum holes.

Abstract: A method for producing a simulated rock by spraying a high density polyurethane elastomer in a flexible rubber mold. The rubber may be natural rubber or synthetic rubber. A rock is produced in molded form, not limited in size. A flexible mold is prepared by applying numerous coats of liquid uncured rubber forming materials, such as latex rubber, upon the rock exterior in combination with a fabric embedded within the rubber latex layers. A supporting cradle for the rubber mold is produced by spraying a low density urethane foam composition over the mold. The mold and cradle are stripped from the rock and are sprayed with a two component structural urethane system employing an isocyanate component and a polyol component with appropriate catalysts, fillers and additives. The structural urethane elastomer is built up to substantial thickness to provide a strong rigid load bearing polyurethane molded rock simulating the original rock surface with curing taking place in a matter of seconds or minutes.

Abstract: A method of forming a coating useful for forming casting molds including agitating a quantity of polyester resin and admixing into the resin a quantity of aluminum powder, storing the mixture for 12 to 24 hours, introducing a catalyst into the mixture and spraying the mixture onto an object defining a mold cavity of a casting mold. The atomized aluminum powder should have a weight ratio of 10 to 50 percent of the resin and should have a ration of 4 times 200 mesh/ 1 times 400 mesh+2 times 200 mesh/1 times 400 mesh.

Abstract: A process for rapidly forming a flexible mold for finely detailed objects from a radiatively curable molding composition includes coating at least a portion of the surface of a three-dimensional object with a fluid molding composition. The coating is cured by exposing the fluid coating to radiative energy to form an elastic, flexible layer of cured molding composition on the object. The coating and curing steps can be repeated to build up the flexible mold until a predetermined minimum has been attained. The cured molding composition is removed from the object, and is suitable for immediate use as a mold to cast duplicate reproductions of the object.

Abstract: A method of making molds which is easy, quick and can be accomplished at room temperatures and atmospheric pressures. The method includes applying at least one layer of gel to a male mandrel and curing at least one layer of polyester impregnated fabric to the gel layer. At least one layer of epoxy impregnated fabric is cured to the polyester impregnated fabric. At least one layer of plaster impregnated is cured to the epoxy impregnated fabric. At least one layer of epoxy impregnated fabric is cured to the plaster impregnated fabric. The resulting mold is removed from the male mandrel.

Abstract: A method of making a porous mold for pressure slip casting. A surface porous layer is cast which has an average pore diameter of at most 20 microns and a thickness of 5 to 40 mm. An adhesive is applied in a pattern to the rear surface of the surface porous layer to leave an unapplied portion on the rear surface. A coarse porous layer is applied to the adhesive applied and unapplied portions of the rear surface of the surface porous layer which is made of a mixture of liquid resin and a filler of a particle diameter of 0.1 to 5.0 mm at a volume ratio of 15 to 50:100. The coarse porous layer has a thickness of 5 to 30 mm. A sealing adhesive is applied to the surface of the coarse porous layer and means is applied for passage of water from and air into the coarse porous layer.

Abstract: An asbestos-free insulating material suitable for use as a header in molten metal casting. The material is made from a dry mixture comprising lime, siliceous component, delaminated vermiculite or spodumene or lithium aluminate or mixtures thereof, and optionally, wollastonite and organic fiber. The dry mixture is mixed with water to form a slurry, shaped, heated in the presence of steam, and dried to remove free water.

Abstract: A composition for receiving and permanently recording impressions including a plastisol, finely ground non-absorbing particulate matter and a small quantity of salt. The particulate matter is limestone and sand.

Abstract: A method and apparatus for manufacturing an otoplastic. An otoplastic is manufactured directly in the ear of a hearing-impaired person in that a deformable envelope is pulled over a die or over a shell or over an overlayed over-shell. This apparatus is then supplied with flowing otoplastic material between the die and the envelope, being supplied therewith in the ear. The envelope expands and assumes the shape of the auditory canal. After hardening or curing of the otoplastic material in the ear of the hearing-impaired person, the envelope and the die are removed and a module of either an in-the-ear or of a behind-the-ear hearing aid is integrated therewith.

Abstract: A mold (1) for cast-molding a slip is provided, which comprises a divsible casting mold including a plurality of mold portions to form a mold cavity (4) when mated together; each mold portion including an air-tight housing (2), an intermediate layer (5) of coarsely porous structure adjacent to the air-tight housing (2), and a solid synthetic resin filter layer (3) of fine open-cell structure; a slip supply duct (8) being connected with said mold cavity (4) and communicated with the outside of the air-tight housing (2); a fluid-flowing duct (9) being connected with said coarse intermediate layer (5) and communicated with the outside of the air-tight housing (2); said filter layer (3) being permeably joined to the coarse intermediate layer (5), and having substantially precise shape and dimension of substantially uniform fine open-cell structure.

Abstract: A method for the manufacture of a mold out of mold material from a previous blank by machining each blank into a desired shape by means of a machine tool controlled by a computer utilizing a dimensioning data set. Each blank is manufactured by feeding an organic polymer material whose melting point is preferably lower than 150.degree. C. in liquid form into a box-shaped container which is open at the top and which corresponds to the dimensions of the desired mold. Waste polymer material from the blank upon machining is recovered and heated to a temperature higher than its melting point, whereupon it is fed onto an existing mold no longer needed, so as to provide a new blank for a new mold.

Abstract: A method and apparatus for manufacturing a composite article by use of a mold core and a cavity block and wherein a skin and insert are placed in the mold cavity and foam precursors are poured into the mold cavity to complete the article includes a process in which a series of part replicas are formed and used to cast thermally stable liners that are carried by the mold core and mold cavity. The thermally stable liners have low melt temperatures and can be reused and recast following wear during the molding process. The liners are made from material which has low shrinkage and expansion rates to define a mold assembly that will produce repeatable parts.

Abstract: By using an existing ball nut and ball nut screw of a ball nut screw assembly as master models, imprint molds can be molded from a silicone rubber material which positively profiles the threading of the ball nut and ball nut screw with the crossover channel in the master model of the ball nut. A thermoset resin is added to the imprint molds and cured to form unitized all plastic ball nuts and ball nut screws with the helical grooving for accommodating the train of balls including the crossover channel in the ball nut molded therein to thereby provide an easily reproducable ball nut and screw assembly.

Abstract: A method for producing simulated rocks by spraying a high density polyurethane elastomer in a flexible mold. The method includes reproducing a rock in molded form, not limited in size. A flexible mold is prepared by applying numerous coats of latex rubber upon the rock exterior in combination with a fabric embedded within the rubber latex layers. A supporting cradle for the latex mold is produced by spraying a low density urethane foam composition over the latex mold. The mold and cradle are stripped from the rock and are sprayed with a two component structural urethane system employing an isocyanate component and a polyol component with appropriate catalysts fillers and additives. The structural urethane elastomer is built up to substantial thickness to provide a strong load bearing polyurethane molded rock simulating the original rock surface with curing taking place in a matter of seconds or minutes.

Abstract: Herein disclosed is a method of making a porous mold by using an upper case which bears lines for forming channels for water and air communications.

Abstract: A method for forming a cast replica of an article, including: forming an outer mold around the article with a first molding material, the outer mold having an inner surface substantially conforming to the outer surface of the article; separating the article from the outer mold; applying to the outer mold on its inner surface a predetermined thickness of a second molding material which is separable from the outer mold, the second molding material defining a hollow space at the interior thereof; filling the hollow space with a third molding material separable from the second molding material; allowing the third molding material to cure to form an inner mold; separating the second molding material from the outer mold and the inner mold; locating the inner mold or a reproduction thereof within the outer mold with a space between said outer mold and the inner mold representing the predetermined thickness; filling the space between the inner mold and the outer mold with a fourth molding material; allowing the fourt

Abstract: A method of reproducing in chocolate a selected image, comprising the steps of optically scanning the image, laser etching the selected image in a surface of a plate in response to the optical scanning such that peaks and valleys are created in the surface of the plate corresponding to the selected image, controlling the laser etching by a scanning laser or a displayed frame of the image, casting a deformable transfer blanket against the surface of the etched plate surface to record in a surface of the transfer blanket peaks and valleys corresponding to the selected image, casting a chocolate material against the surface of the transfer blanket to record the selected image by peaks and valleys in a surface of the chocolate, and removing the cast chocolate material from the transfer blanket.

Abstract: A method of making a porous mold used in pressure casting for forming ceramic articles, which includes the steps of: removably attaching a plurality of apertured holding members in an array at a desired interval to the inner face of an upper case made of a rigid material; threading a flexible line into the apertures of the holding members in each row to hold it at a predetermined spacing from the inner face of the upper case, at least one of the two ends of the flexible line being extended to the outside of the upper case; casting slurry into a mold cavity which is defined between the upper case and a lower basic case joined to the former case to form a porous mold; removing the upper case from the porous mold after the slurry has cured, while leaving the holding members together with the flexible lines in the porous mold; and extracting the flexible lines from the porous mold to form channels in the porous mold.

Abstract: A method of making epoxy molds for making wax patterns have metal posts disposed therein which transfer compressive forces between the force applying members of the press in which the molds are located. The metal cylinders in the upper mold section have right hand screw threaded axial bores and the metal cylinders in the lower mold section have left hand screw threaded axial bores. The metal cylinders are connected together when the mold sections are poured by connecting studs which have oppositely threaded ends. After the epoxy cures, screw drivers are inserted into the threaded bores from outside the molds and the connecting studs are turned in a direction which causes the mold sections to separate in turnbuckle fashion. Accurate alignment of the inner end faces of the cylinders in the parting surfaces of the mold sections is achieved by having the metal posts connected during the mold pouring steps.

Abstract: A method of making a mold used in a pressure slip casting process, including the steps of: preparing at least two porous bodies each defining a filter layer having a plurality of channels formed therein for allowing water and air to flow therethrough; placing a reinforcing iron frame and one of the porous bodies on a bottom board with a parting agent applied to its surface; applying a sealing resin to the surface of the other porous body opposite to a molding surface thereof and to a portion of the surface of the bottom board between the box and the porous body; filling up the space between one of the porous bodies and the reinforcing iron frame with a filler; and preparing a second part of the pressure mold.

Abstract: A novel manufacturing process of mold containing continuous holes and used for filter materials, gas dispersive materials, and mold materials. By this invention, the epoxy resin mixture including an epoxy compound having one or more epoxy groups in each mole, a hardener which reacts with and hardens the epoxy compound, emulsifiers, water or water-surface active agent, and fillers respectively is used as the molding material. As the emulsifier, at least two kinds of three different kinds of nonionic emulsifiers of 4-8, 8-17, and 11-15.6 HLB respectively are used together.The molding material is cured to a desired shape to prepare a mold containing continuous holes and for molding, conventional methods such as hardening after casting, for example, are adopted.

Abstract: A method for forming a composite door to custom fit a predetermined door opening. A template is formed by spraying a quick hardening foam on a door jam of the door opening. The template is moved a base member of the tool and the base member adjusted to conform to the shape of the template. A mold is formed using the template and base member. Composite material placed inside the mold and on top of the base member forms a door to custom fit the door opening.

Abstract: A flexible surface plywood concrete form liner is disclosed which includes a flat planar sheet of relatively thick plywood material which has been precisely sized and squared. The prepared plywood sheet material is coated with a layer of relatively thin, flexible elastomeric material cast as a one-piece layer over the entire surface of one side of the plywood sheet material as well as all four edges. In this way, the elastomeric material is a continuous integral coating bonded directly to the surfaces of the plywood to prevent the penetration of moisture or chemicals from the concrete into the laminations of the plywood during use. A textured negative impression can be provided on the outer surface of the elastomeric material to leave a textured surface in the finished concrete. A novel edge seal which can be slightly angled is formed along the edges of the liner so that the joint between the liners is reinforced to strengthen and prevent blow-out of the concrete at the liner joints.

Abstract: A method of forming a bezel that contacts and/or substantially envelops a gem without altering the same is presented. A replica of the gem is initially formed about which a temporary bezel is crafted having the desired artistic markings thereon. In a lost wax process, the temporary bezel is replaced by a permanent bezel. Then the replica is destroyed. In another aspect of the present invention, a replica mold material for use in this process is also disclosed.

Abstract: A dark field ultrasonic transducer is constructed with an outer annular spherical or conical transducer element and an inner spherical element. The outer annular element is excited and insonifies a small portion of a part surface near a discontinuity or crack with longitudinal waves or with surface waves. The inner dark field element is not focused to be sensitive to either reflected sound or waves reradiated from the surface waves, but detects sound scattered from surface discontinuities such as a crack edge. When surface waves strike a crack edge and restrike it after reflection from the bottom of the crack, two pulses are received and the time delay between them is a measure of crack depth. The crack shape and crack depth profile are determined as the part is scanned. A sphere-cone transducer, the preferred embodiment, is fabricated by stretching thin piezoelectric polymer film over a tool having a ball embedded in a conical surface.

Abstract: Webs for reducing bending in board-shaped construction elements when in use have their main direction of load perpendicular to the board plane. The devices have a sandwich of at least one first material layer, one second material layer, and one third material layer. The third material layer lies between the other two material layers and has a substantially higher coefficient of heat expansion than the other two material layers, so as to set up contracting biasing forces in the third material layer. The third material is made of a sheet metal strip. The two other materials are made of thermosetting plastic, which sets at a temperature considerably above the working temperature of the construction element.

Abstract: Molds for injection molding are produced by providing a primary mold core, coating the primary mold core with a water-resistant coating layer, applying on the water-resistant coating layer a separating layer, spraying a metal shell on the separating layer, arranging a rear filling on the shell so as to form a tool part, and supplying water to the water-soluble layer so as to remove the tool part.

Abstract: A decorative speaker cover and a method for fabricating a speaker cover for use in a ceiling or wall comprising panels, the speaker cover having an appearance which blends with other panels so that it conceals the presence of a speaker system while providing satisfactory transmission of sound from the speaker system. The decorative speaker cover is fabricated by first forming a mold liner suitable for generating a facsimile of a ceiling or wall panel. Next, the mold liner is placed in a molding container and a closed cell expandable foam system is uniformly spread over the mold liner so that the foam rises vertically. The thickness of the resulting cast is reduced to a dimension below which acoustic transmission loss is not discernable by human ears.

Abstract: A process of producing plastic-molded printed circuit boards by injection-molding a heat resistant plastic to form a plastic molding having many perforations and forming a conductive layer on the molding, which comprises molding the heat resistant plastic using a mold for injection-molding obtained by preparing a die set for injection-molding composed of a fixed side metal platen having at least an inlet for molten resin and forming a space for installing mold part(s), a stripper metal platen having, if necessary, an inlet for molten resin connected to the fixed side metal platen and forming a space for installing mold part(s), and a movable side metal platen forming a space for installing mold part(s); and assembling a pair of molds composed of a mold I having a concaved portion for cavity and a mold II having perforations for passing hard pins for forming holes and, if desired, a concaved portion for cavity, said molds being formed by a cured resin composition or a composite of a metal and a cured resin com

Abstract: A method of forming a substrate for manufacturing single crystal thin films, wherein the substrate is a replica pattern of a monocrystalline or single crystal cleavage plane. Such replica pattern may be formed by pressing a material in a softened state against the cleavage plane of the single crystal, with subsequent hardening, and also, by subjecting the single crystal cleavage plane to vapor deposition or plating, and thereafter removing the formed layer from the single crystal cleavage plane.

Abstract: Accurate heads are prepared by molding processes for the use by taxidermists in preparing fish for permanent display. The heads are removed from the silicone rubber mold just after the molding composition has achieved its peak exotherm and becomes very firm.