Abstract: A process of making a full life size artificial rock formation of photocopy exactness from a natural rock formation surface is disclosed herein. A plurality of coats of latex is applied over the natural rock surface and allowed to dry thus forming a mask having all the natural cracks and crevices of the natural rock surface. This mask or liner is held in a fiberglass mold and a vacuum is applied to the inner surface of said liner causing all the cracks and crevices to open up. Cement is applied to the outer surface of the liner filling all the cracks and crevices. When the liner is removed the artificial surface resembles the natural rock surface in photocopy exactness.

Abstract: A method of forming an image with photographic likeness on a chocolate material is disclosed. The image is "developed" on the chocolate material by means of an edible developer.

Abstract: An improved method of forming a decorative panel of molded plastic comprising the steps of constructing a form having a detailed masonry surface; covering the detailed surface with a mold release material; applying a thin layer of gel coat over the mold release; applying a plurality of layers of fiberglass matte and resin over the gel coat layer; allowing the plurality of fiberglass matte and resin layers to harden thereby forming a heat resistant mold having a female side being formed against the detailed surface and a side opposite from the female side; removing the mold from the form; perforating the mold thereby providing fluid communication between the two sides; connecting a vacuum apparatus to the side opposite of the mold; placing a sheet of high impact plastic above and adjacent the female side of the mold; activating a heater thereby heating the plastic sheet to a pliable state; activating the vacuum apparatus thereby drawing the plastic sheet into the female side of the mold; and removing the forme

Abstract: The invention relates to a method for forming an article by injection molding, such as a shoe, and comprises the formation of a mold (5) by coating a master pattern of the article with a pourable, heat-resistant molding compound, such as an epoxy resin or polyurethane. The master mold (5) so formed is secured in a mold casing (1) for an injection molding plant and molding material such as poly-vinyl chloride or polyurethane is injected to form the finished article. The master mold may be formed directly in the mold casing (1) to which it can be secured such as by mechanical securing and located means (6,7,8,) or by being adhered thereto. In an alternative embodiment of the invention, the master mold may be formed in a mold box and subsequently fitted into the mold casing (1) for reproduction of the article.

Abstract: A dry wall interlocking building block system includes a method of manufacturing moulds for casting building blocks, in which master forms corresponding in shape and size to the required blocks are cast from a cold-pouring compound in collapsible core-boxes, and in which a mould is built up around the master forms (7) by securing the forms to a casting table (8), placing metal liner plates (9) against the sides of the forms, filling the spaces around the liner plates with a similar cold-pouring compound, allowing the compound to set, and withdrawing the forms to leave a plurality of mould cavities. The mould can then be mounted in a block making machine for large scale casting of concrete blocks in the mould cavities. One feature of the preferred mould is that the liner plates are detachable, countersunk bolts (10) having been fitted in holes in the liner plates (9) prior to filling the spaces around the plates. The invention also includes a two-recess building block cast in the above mould.

Abstract: A tool for use in a latex dip process for producing a latex skin in a given configuration, the tool being formed by producing an electro-formed female mold from a sculpture of the desired configuration, casting a vinyl skin from the electro-formed female mold, removing the vinyl skin to expose a hollow interior, and stuffing the vinyl skin with a composition of materials, having the characteristics of providing rigidity to the vinyl skin and approximately zero buoyancy in a latex bath.

Abstract: Leather sheets having desired grain pattern are mounted on a roller with edges abutting. Onto the surface of the grain pattern a silicone synthetic resin is applied as a uniformly thick coating with a coating knife as the roller rotates. The resin is hardened into a matrix. It is then peeled off the grain pattern. The grain pattern in the matrix is interrupted where the leather sheets abutted. The matrix is placed with the pattern outward on a roller whose diameter pretty much matches the diameter of the embossing roller to be produced. The surface of a tubular thermoplastic film is embossed by contact with the cylindrical matrix under heat and pressure. The embossed surface of the thermoplastic film is once again overembossed under heat and pressure in the areas along the abutting edges of the natural grain pattern on the roller, so that an endless positive impression without seams in the grain's pattern is produced.

Abstract: A method of making jewelry or the like to enhance the retention of a gem to a retaining bezel area of the jewelry, comprising the steps of obtaining and utilizing the gem as a model initially, casting the gem in a moldable material, allowing the moldable material to set, dividing the set moldable material into segments to expose the gem, thereby providing a recess in at least two divided moldable material segments thus formed, removing the gem to expose the recesses, casting into the recesses a material which is soluble in the presence of a fluid so that the cast material has an external configuration of the gem when set, allowing the cast material to set, removing the cast material from the recesses of the moldable material, crafting a temperature sensitive substance about the cast material to form the bezel area and attendant jewelry, removing the set soluble material in the presence of the fluid, vaporizing the temperature sensitive substance with molten material using a lost wax process, allowing the molt

Abstract: Disclosed is a coating die which has a dilatable orifice, the orifice being dilatable due to the use of a flexible, resilient portion of the die. The die is individually cast and is "strung-up" in the casting process. The preferred use for the die is in the coating of textile filaments, especially small diameter filaments that are slubby.

Abstract: The addition of the metal drier to the phenolic urethane binder enhances the breakdown of the binder when the system is subjected to the elevated temperatures caused by pouring the molten metal into the mold and enhances the subsequent shake out of the sand from the cores and molds.

Abstract: A process for forming a hollow, cured composite article. The process includes steps of making a plug from a meltable material. The plug is covered with a polymerizable material and the covered plug is inserted into a cavity formed in a thermally-expansive and heat-resistant polymer held within a rigid container. The almost filled container is covered and the container and part are heated to cause curing of the polymerizable covering. The cured assembly is removed from the thermally-expansive and heat-resistant polymer and heated to an extent sufficient to melt the core.

Abstract: Very large tools can be cast-to-size by making a pattern of the article to be formed by the tool, laying the pattern up in a pattern box, applying a release coat and coating the pattern and box with a tough, curable tool surface layer. A small amount of epoxy filled with a thermally conductive particulate filler is cast into the pattern box before the surface layer fully cures. Relatively large chunks of thermally conductive material are added to the box which are covered with additional cast epoxy. The cure of the epoxy is controlled to effect complete cure at room temperature within a few days but never to exceed a peak cure temperature above about 70.degree. C.

Abstract: A method of producing a unitary curved structure having a honeycomb core by coating a mold with gel, applying a layer of reinforced fiberglass plastic to the gel to receive, after partial curing, a light layer of chopped glass fibers (about 3/4 ounces/sq. ft.) and a mixture of catalyzed resin and chopped fiber strand. The resulting surface may be rolled to remove bubbles and oversprayed with catalyzed resin. A Raw Kraft paper honeycomb is placed into the wet laminate and completely covered with wax paper weighted with sand bags to approximately 10 pounds per square foot to press the honeycomb into place and seal same. The resin is absorbed in and climbs the honeycomb walls, and heat and styrene gas are liberated into the cells. The bags and wax paper are removed after partial cure, excess styrene fumes are blown away, and the honeycomb is lightly oversprayed with a catalyzed resin.

Abstract: A method for producing the matrix for the embossing cylinder which has a uniform pattern design in the marginal areas adjoining the abutment where the ends of the blanket are joined to form the tube comprising (1) casting liquid silicone rubber on a sheet of leather having the desired grain and vulcanizing the silicone, (2) using the matrix thus formed to emboss, under heat and pressure in a press, a rectangular sheet of thermoplastic resin such as polyvinyl chloride film, (3) forming the embossed sheet into a tube, (4) placing the portion of the tube having abutting edges in a narrow platen press and reembossing the area surrounding the abutment with the silicone rubber matrix to mask the impression of the joint and provide a continuous uninterrupted pattern, and (5) using the positively-embossed thermoplastic sheet as a matrix for casting vulcanizable silicone rubber to form a negatively-embossed matrix for use as a blanket on an embossing roll.

Abstract: In order to remove a thin-walled wax model adhering to the walls of a first core piece and a second core piece, after solidifying, from a multi-part device for making thin-walled wax models, without damaging the wax model, after the external pressure is released, a mold-opening moment is generated simultaneously and abruptly in axially opposite directions by spring-loaded push-off bolts or directly by leaf springs in the upper parting faces and lower parting faces of the device. As a result, both the lower closing plate and the upper closing plate are separated from the annular casing and the wax model is separated from the core pieces, by a maximum of 3 mm, axially in opposite directions because the adhesion of the wax model to the walls of the core arrangements is overcome simultaneously and abruptly. Subsequently the two core arrangements and the casing are transported away from one another in an axial direction relative to one another, so that the wax model is freed.

Abstract: A forming tool made from resins and fillers for the cold forming of sheet metal and especially suitable for forming short runs of sheet metal parts with drop hammers, hydraulic presses or mechanical crank presses, the filler being a mixture of iron filled resin and an aggregate; the aggregate being a lightweight by-product of the steel making process.

Abstract: An apparatus and method for cold retreading of the running surface of a vehicle tire. A rubber and cloth mold is produced utilizing a new tire male mold covered with perforated polyethylene film, uncured rubber and highly stretchable cloth enclosed in an envelope and cured by application of pressure and heat. The somewhat flexible female mold thus produced is then utilized in recapping tires by positioning it around a prepared tire carcass coated with cement, a layer of uncured rubber, and a sheet of perforated polyethylene film. The mold and tire assembly is then enclosed in an envelope, and like assemblies are placed in a chamber where curing of the rubber layer is accomplished by inflation of the tire carcass, evacuation of the envelope, pressurization of the chamber and application of heat.

Abstract: A method of molding stone-faced pillars comprising attaching stone pieces onto a wooden base, covering the surface of said base, not covered by the stone pieces, with Plaster-of-Paris, spraying numerous coatings of latex rubber on the entire base and stone pieces of the pillar and spraying numerous coatings of liquid base fiberglass on said coatings, peeling off said coatings, and laying them in right angular relationship in a right angular mold and finally pouring wet cement onto the stone-faced portions to reproduce the stone faced pillar model.

Abstract: A mold, useful in preparing Tiffany-like lampshades, terrariums and glass lamp bases is described. The process for preparing this mold, which produces sections of a 360 degree unit within which the assembler works, is also described.

Abstract: A tough, flexible, sheet-like matrix for a bas-relief pattern is made by casting a reinforced resin on a mold of the pattern and submerging a perforated plate in the liquid resin so that the plate is parallel to a substantially flat plane generated by the lowest points of the pattern. The matrix, exclusive of the peaks and valleys of the pattern, has a uniform thickness and has a multitude of studs integral with and dependent from the sheet. A porous matrix is useful for the wet-end texturing of fiberboard at the final suction press roll of a Fourdrinier fiberboard machine.

Abstract: A polyol gel is made from 15-62 wt. % (based on the sum of polyurethane matrix plus dispersing agent) of a high molecular weight covalently cross-linked polyurethane matrix; 85-38 wt. % (based on the sum of polyurethane matrix plus dispersing agent) of a liquid dispersing agent which is firmly bonded to the matrix; and optionally, active ingredients, fillers, additives, catalysts, and mixtures thereof. The liquid dispersing agent is a polyhydroxyl compound having a molecular weight of between 1,000 and 12,000 and an OH number between 20 and 112. This dispersing agent should have virtually no hydroxyl compounds having a molecular weight below 800 present. These gel compositions may be used to make mold impressions and highly stable active-ingredient releasing compositions.

Abstract: A racket structure to be used in a tennis and the like racket and a method for producing it, where the handle section and the head frame section are made of a one-piece composite member including an inner light weight soft plastic core member having a central prestressed multifilament cord member and a glass fibers reinforced hard plastic, outer surrounding layer, anchored on said core member within the head frame section, said surrounding layer being covered on opposite faces with respective resilient flat cover members which also sheath part of the height of said head frame section on the inside face, facing the netting, defining the striking surface stretched in the oval space defined by the head frame section of the racket.

Abstract: A flowable slidifyable mass is applied onto the inner surface of a hull made of an elastomeric material and corresponding to the human skin section. This flowable mass is let to solidify into a shell-like body. Thereafter the shell-like body is cut and machined such to produce an article corresponding in shape to a portion of the human skeleton. A molding mass which solidifies to a flexible body is injected into the void space defined by the elastomeric hull stretched over the skeleton portion such that a flexible negative form of the skeleton is produced. Thereafter the elastomeric hull, the negative form and the skeleton portion are separated from each other and the elastomeric hull stretched over the negative form only and a further molding mass is inserted into the void spaces defined by the elastomeric hull and the negative form such that an arbitrary number of skeleton portions can be produced.

Abstract: A carbon fiber-reinforced cement mould is provided which is capable of being thermally cycled continually at temperatures up to 200.degree. C. Such mould is particularly suitable for casting or forming plastic articles which require heating up to 200.degree. C. to effect curing. Because the mould remains free from cracking and surface spalling during such thermal cycling, it can be used over and over again.

Abstract: This invention comprises a process for molding a three dimensional decorative article where cored out or raised portions extend to a depth of at least 0.6 centimeter, said process comprising generating electronically a line drawing of said article and electronically displaying the drawing; photographing said drawing to form a photographic transparency; positioning said transparency over a layer of a liquid photopolymer having a depth greater than 0.6 centimeter; exposing said photopolymer through said transparency to actinic light to set the photopolymer; and removing the liquid from the set photopolymer to form a three dimensional article having the appearance of said drawing.

Abstract: The invention provides a novel method for the preparation of an electric connector formed of a core rod of an insulating rubber and a stripe-wise annular zones of a layer formed of an electroconductive paint to exhibit an appearance something like a brandling earthworm. According to the invention, a strip of a plastic film bearing printed stripes of the conductive paint is introduced lengthwise into a tubular mold with the printed surface facing inwardly to take a tubular configuration in direct contact with the inward surface of the tubular mold and the printed surface is brought into contact with the surface of the core rod so as that the striped layer of the conductive paint is transferred and adhesively bonded to the surface of the core rod, each stripe forming substantially closed ring on the core rod. The core rod may be an pre-formed rubber rod or formed by in-mold curing of a liquid prepolymer convertible into a rubber.

Abstract: A method for manufacturing a heat-insulating member, such as e.g. a door or housing of a refrigerator, including a shell and a foamed heat-insulating material filled in the shell and a jig used therefor. The jig is intended to hold the shell lest the shell of the heat-insulating member to be manufactured should be deformed when a foamable liquid composition is foamed in the shell. In the jig of this invention, a jig body is formed of a heat-insulating material. The method of this invention comprises the steps of holding the shell in a hollow state by means of two jigs, injecting the foamable liquid composition into the shell to foam the same in the shell. Since the jig body of the jig of this invention is made of a heat-insulating material, the necessity of external heating, which is essential to the conventional method, is substantially obviated.

Abstract: A fluid-release mold is disclosed. The mold includes a preformed, porous mold body having a mold face formed on a first exterior surface and a second surface. A groove is formed in the second surface. A tape covers the groove to form a conduit between the surface of the groove and the surface of the tape facing the groove. The conduit directs pressurized release fluid to the mold. A fluid impermeable backing material is disposed over the second surface of the mold body whereby egress of the fluid from the conduit is prevented except through the mold body in a direction away from the second surface.

Abstract: An improvement is disclosed in the matrixing process employed in the manufacture of molded records. The improvement consists of using an insert in the matrixing process which is secured to the center portion of the matrix to be duplicated prior to electroforming a replica on the surface of the matrix. Metal is then electroformed over the surface of the matrix and the insert to form the replica and the insert is thereafter used to apply force at the center portion of the replica to force it away from the matrix on which it is formed.

Abstract: A method and means for contructing a three dimensional contour relief map, or the like, which comprises a housing having the opposite ends thereof open and having a plurality of upright side-by-side tubes disposed therein, the lower open end of the housing being in communication with a liquid reservoir, the lower end of each tube being open to the liquid through a check valve for controlling the admission of the liquid into the interior thereof, and the upper end of each tube being open, a pantograph type tracing or scribing instrument having a tracer for movement along the contours of the map being transformed into the three dimensional scale model and having an arm member movable over the open upper ends of the tubes simultaneously with the scribing of the map contour lines, a vacuum source in communication with the open upper ends of the tubes through the arm passing thereover for creating a selected pressure differential between the interior of the respective tube and the ambient pressure acting on the su

Abstract: Identical half-section shells of microscopic size, such as hemispherical shells from which spherical laser fusion targets can be made are capable of mass production by micro fabrication molding techniques. A body (preferably a hollow glass microsphere which is called a glass microballoon) provides a pattern for the hemispherical shells, and is used to produce an original mold section. One or more master molds are formed from this original mold section by replication. Many identical replica molds are made by casting soluble material onto the master mold and removing them therefrom. The replica molds are coated with one or more layers which will form the hemispherical shell wall. The material coating the flat background around the hemispherical cavity is referred to as the flange and is removed to form free standing shells. In order to remove the flange material, the coated replica molds are overcoated with a soluble material which is etched away to the level of the flange.

Abstract: A method for making cast precision epoxy resin bodies and an epoxy resin formulation for use therein, the epoxy resin formulation having Component A consisting essentially of from 40 to 70% by weight epoxy novolac polymer, from 30 to 50% by weight vinyl -3-cyclohexene diepoxide and from 0 to 20% by weight 3,4 epoxy cyclohexylmethyl -3,4-epoxy cyclohexane carboxylate and Component B consisting essentially of partially hydrolyzed aryl tetracarboxylic acid dianhydride, preferably partially hydrolyzed pyromellitic acid dianhydride. In the preferred embodiments a tertiary amine catalyst is also included. These components are mixed, just before use, in a ratio of from 20 to 50 parts by weight Component B to each 100 parts by weight Component A.

Abstract: Disclosed is a method and apparatus for forming indicia on the outside of a roto-molded plastic container during the roto-molding process wherein a template bearing a mirror image of the indicia is removably affixed to the interior wall surface of a mold.

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

Abstract: A slip-casting system utilizing a ceramic powder for the mold. The system facilitates casting thin-walled and/or long objects without additives for demolding.

Abstract: A molding kit to facilitate the synthetic cloning of body parts, such as fingers, the kit including a supply of alginate powder and a mold form having a bottom opening that is sealed when the form is seated on a base. A charge of powder is mixed with water to form a quick-setting, flowable molding compound. This is poured into the mold form, after which the body member is inserted and held therein until the compound sets to form an elastic gel. The gel is then pushed out of the mold form through the bottom opening, and the body part withdrawn to expose the impression cavity. The gel is returned to the mold form which is again seated and a flowable casting compound of the same composition as the molding compound is poured into the cavity and permitted the set to create a flesh-like clone of the body part. This clone is readily removable from the cavity without marring the impression therein.

Abstract: A method is provided for making shaped self-supporting carbon-fiber structure by initially forming a fluid mixture of curable binder and carbon-fiber. The mixture is poured into a mold, and a vacuum is applied to the mold to effect the separation of excess binder. Cure is effected of the residual binder to produce a removable self-supporting shaped carbon-fiber structure.

Abstract: Disclosed is a method and apparatus for forming indicia on the outside of a roto-molded plastic container during the roto-molding process wherein a template bearing a mirror image of the indicia is removably affixed to the interior wall surface of a mold.

Abstract: A method and apparatus for replicating the submerged surfaces of ships and other marine structures. One apparatus includes a housing which is partitioned into forward and rear chambers by a membrane and a piston member, which is carried by the membrane. Upon selective flooding of the rear chamber and evacuation of the forward chamber, the piston member is moved toward the submerged surface to form an evacuated molding region therebetween. Liquid molding material is then drawn into the evacuated molding region and the molding device is retained in position until the material solidifies.An alternative molding apparatus includes a housing with peripheral suction elements for releasably securing the housing to the submerged surface so that a molding region is defined therebetween. Upon displacement of water from and subsequent evacuation of the molding region, settable molding material is introduced into the molding region.

Abstract: A method of making a polypropylene printing plate using a paper matrix in which a roll and an opposing member are prepared, a paper matrix is attached to one of the roll and opposing member, a crystalline ethylene-propylene copolymer having a MFI (melt flow index) of 3.about.10, containing ethylene less than 20% by weight and tensile yield strength of 220.about.330 kg/cm.sup.2 is continuously fed under molten state between the roll and the opposing member, and then the crystalline ethylene-propylene copolymer is pressed and cooled to be hardened.Further, a reproducing printing plates consists of a crystalline ethylene-propylene copolymer whose melt flow index is selected in a range of 3.about.10, which contains ethylene less than 20 weight % and which has the tensile yield strength of 220.about.330 kg/cm.sup.2.

Abstract: An improved method of reproducing a spiral groove pattern in the surface of a plastic disc wherein the intersections of the surface of a metal article generated during the replication process are filled in to form concave junctions.

Abstract: The molding process comprises pouring a plastic compound around a natural tree trunk to make a mold which has the tree trunk surface impressed therein. The plastic mold is supported in a frame made from wood which has a galvanized metal support therein. The metal brackets and structural rods are positioned on the base of the frame and a plastic core member may be used and removed to create the hollow interior of the tree trunk base.

Abstract: A composite cylindrical mold for making rubber covered rolls comprises an outer rigid tube and an inner hollow cylindrical sleeve, with the space between the tube and the sleeve being filled with a cured elastomer. In preparing the mold, a heat shrinkable polytetrafluoroethylene tube etched on the outer surface is disposed around a rigid mandrel and heat shrunk thereon. The mandrel and sleeve are then inserted into the rigid tube in concentric relation. Curable rubber is then injected under pressure between the tube and the sleeve and the rubber is cured, causing the inner surface of the sleeve to conform exactly to the surface of the mandrel. The mandrel is then removed, and the inner surface of the sleeve is used as a molding surface for rubber covered rolls.

Abstract: An element having a molding surface defining the cavity of a mold for molding thermoplastic resin and a method of making the element. To regulate the cooling speed of the molten resin to be injected or placed into the cavity, the molding surface is provided by a thin metal layer and a layer of heat insulating material is formed on the inner side of the metal layer.

Abstract: A method for repairing grained or embossed vinyl sheeting with imprinted vinyl molds is provided, whereby the repaired area is grained or embossed in the original pattern without the application of pressure, thereby eliminating depression or deformation in the repaired vinyl sheeting.

Abstract: This invention concerns a method for forming thinwall structures from fiberglass, ferrocement or similiar materials in shapes that are inherently optimum in cost-strength effectiveness. Reinforcing means are hung from elevated points forming a catenary surface and then saturated with a post setting material. The structure is inverted after it is stable onto mirror image supports causing its elements to be in compression with negligible bending or tensile stresses.

Abstract: A method of producing an indicia transferring surface including affixing an inert material in the shape of indicia to a base sheet containing a curing inhibitor coating. A curable compound is placed on the surface of the base sheet in contact with the indicia shaped inert material and is allowed to cure. After a curing period, the curable compound is separated from the base sheet. The curable compound includes a cured portion and an uncured portion. The uncured portion is removed, leaving raised areas of the cured compound that were in contact with the indicia shaped inert material. The raised areas may then be used to transfer the impression of the indicia to another surface.

Abstract: An insulating corrugated member is provided by two sheets having identical corrugations, at least one of the sheets being of a thermoplastic material and having its edges deformed, the deformed edges being adhesively secured to the other sheet. The edges of the thermoplastic sheet are deformed on a mold which is prepared by using, as a template, a sheet having identical corrugations by the application of heat and differential gas pressure to opposite sides of the thermoplastic sheet.

Abstract: A method is disclosed for the preparation of implants, especially dental implants, from ceramic substances having in particular a porous surface which stimulates ingrowth of bone tissue.

Abstract: A first mold is made by mounting a plurality of semicircular ribs of a relatively large radius on a board in spaced relationship and centered along an arc on the board with the ribs extending generally radially of the arc and having diametral portions of their peripheries facing the board, foaming a foamable hardenable liquid resin in place between each pair of adjacent ribs, and applying hardenable liquid resin over the ribs and foam. A glass fiber reinforced outer jacket for insulation is formed on and removed from the first mold. A second mold is made similarly to the first but using semicircular ribs of a relatively small radius. The outer jacket is mounted on the second mold and the space therebetween has foamable hardenable liquid resin inserted therein to form a jacketed longitudinally curved semicircular section of foamed resin pipe insulation.