Abstract: A method of making a mold from a model is disclosed. A mold carrier is formed having an aperture therein. The aperture has a configuration generally corresponding to the shape of the model. The model is positioned within the aperture such that a space is created between the outer peripheral surface of the aperture and the outer peripheral surface of the model. A resilient first material in its liquid state is poured into the space such that the first material substantially covers the outer peripheral surface of the model. The resilient first material is allowed to solidify in the space such that a resilient mold insert is formed. The mold insert forms an impression of the outer peripheral surface of the model and is disposed along the inner peripheral surface of the aperture. The model is removed from the resilient mold insert. A second material in its liquid state is poured into the aperture of the mold carrier with the resilient mold insert disposed along the inner peripheral surface of the aperture.

Abstract: The tire mold having a surface 5 of open porosity which covers at least in art certain of the molding surfaces 10 and 20 in order to assure the venting of the mold.

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: 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 method of making a die and the die itself for establishing through embossing or micro-embossing a seamless pattern, preferably a holographic pattern, on a decorative medium such as a metallized film is provided. A cylindrical embossing or micro-embossing die is provided with a layer of an embossable material, preferably pure silver, a silver alloy or any other suitable embossable material. The cylindrical die is an integral member in which a pattern is recombined thereon by a step and repeat embossing or micro-embossing process as opposed an intricate lathe-type machine-turning operation, and can thus accept, carry and maintain complex patterns with the integrity required for producing a repeating holographic pattern.

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: A method including: based on a primary mold having a surface pattern identical with that of a composition to be produced, making a secondary mold having a low melting point sprayed metal layer of Zn or the like to which the surface pattern of the primary mold is transferred; next, after carrying out mold-releasing treatment on the secondary mold surface, spraying a high melting point metal such as Ni or the like; reinforcing the back side of the thus-formed high melting point sprayed metal layer with FRP or the like; hardening said FRP or the like; and then, releasing a composition consisting essentially of the high melting point sprayed metal layer and the reinforcing resin layer from the secondary mold.

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: 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 three-dimensional master of the article to be molded is provided. The surface of the master is coated with a mold release agent. A gel coat layer is then applied to the mold release agent coated surface of the master, and cured at about room temperature and preferably no greater than 55.degree. C., until the cured surface feels slightly tacky. At least one fiber-reinforced catalyzed resin layer is then applied to the cured gel coat layer and cured. The resin layer includes a room temperature curing, low shrinkage thermosetting filled paste system including 25 to 75 percent of an unsaturated polyester resin, 1 to 25 weight percent of a mixture of thermoplastic polymers of vinyl acetate, an epoxy compound having at least one 1,2-epoxy group per molecule, and 25 to 75 percent filler. The resin is preferably cured at room temperature for about 30 minutes to 4 hours using a free radical initiator which is mixed with the resin as it is being applied.

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: An elastic mould of this invention includes a pattern and a fixing sheet which is integrally mounted at an open edge of the pattern. The elastic mould is manufactured by dipping a pattern mounted on a plate into an elastic body-producing solution to form a gel-like elastic film, withdrawing, drying and vulcanizing the object thus formed, and peeling the elastic film off the pattern to obtain a mould having a fixing member as an integral part of the mould.

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: This invention relates to investment casting compositions comprising (i) a refractory material, e.g., a ceramic material, and (ii) a soluble core material comprising one or more block polymers characterized by an ABCBA structure. This invention also relates to methods for investment casting and to the manufacture of molded articles. The soluble core materials exhibit desirable breaking strength, dissolution rate and surface characteristics.

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 shell mould, particularly for a lost wax casting operation, includes the deposition of an adhesion agent on the pattern before the deposition of layers of ceramic material to build up the mould. The adhesion agent used is preferably a 3% solution of aminosilane in a solvent consisting of ethanol and ethyl acetate in amounts from 25% to 75% of the solvent. The method avoids the phenomenon of detachment at the pattern/ceramic interface.

Abstract: A method of producing a prosthetic implant for a predetermined organ site. Three-dimensional data including surface contour information of the organ site is obtained and a physical life size model of at least a part of the surface contour of the organ site is produced based on the three-dimensional data. Thereafter, an implant model is formed onto the surface of the physical organ model, and a prosthetic implant is produced from the implant model using a casting process.

Abstract: A matrix as shown in FIG. 3 and suitable for use in an injection molding process or a compressing molding process for the manufacture of optically readable information carriers comprising an optically readable information track, in which the matrix comprises a metal supporting plate 11 which on one side comprises a layer of a radiation-cured synthetic resin composition 8 comprising the negative of the information track.

Abstract: A process for forming a plurality of interfitting sculptured pieces of irregular fanciful shapes having complementary curved surfaces. The pieces are formed of urethane plastic or other appropriate molded material.

Abstract: The impressions are produced using an original plate (19) bearing a design by the following steps: a plastic plate (4) made of thermodeformable material is prepared and placed, in an adjusted position corresponding to the location of the first impression to be produced, between an electrode (7), the outline of which corresponds to the periphery of the design and which is surrounded by an insulating border (24), and the original plate (19) which forms a second electrode; the first impression is produced on the plastic plate (4) by high-frequency heating of the plastic plate (4) via the electrodes, and by compression; the plastic plate (4) is then cooled, the original plate (19) is separated from the plastic plate (4) that is displaced successively in the other adjusted positions corresponding to the other impressions to be produced and, in each position, the heating, compression and cooling steps are repeated in order to reproduce the next impression.

Abstract: A process for producing improved gypsum models and molds of high duplication accuracy is provided. In the process, bundles of carbon fibers of specified length and amount having a sizing agent deposited thereon are treated to remove the sizing agent from the carbon fibers which are then separated into single fibers in water. A major part of hemihydrate gypsum (CaSO.sub.4.1/2H.sub.2 O) powder is then added to the carbon fibers dispersed in water to obtain a gypsum slurry having the carbon fibers uniformly dispersed therein. The slurry is then cast to obtain the models or molds.

Abstract: A method for making reusable mold halves whereby mold aligning perturbations are directly formed in the process. Two mold parts are superimposed, one having a cavity for retaining the mold to be reproduced and the other having cavities for forming the perturbations. A molding compound is introduced into the cavities which, upon hardening, forms a first mold piece including the model and the perturbations. The mold piece is retained within one of the mold parts, turned upside down, and superimposed with another mold part. Molding compound is introduced into the assembly and hardens to form a second mold piece formed with recesses that are complementary to the perturbations. The mold pieces are separated from the mold parts and the model is removed to form two aligning mold halves.

Abstract: A method of forming a slush mold and a synthetic resin skin utilizing the slush mold. The method includes the steps of roughing a foamed synthetic resin surface to define a prototype having a plurality of irregularly spaced and irregularly sized recesses, forming a metal mold to have a molding surface accurately complementary to the prototype surface and molding a skin of synthetic resin against the molding surface of the metal mold. The recesses preferably have a cross section dimension in the range of approximately 170 to 500 microns and a depth in the range of approximately 8 to 133 microns. Narrower preferred ranges are disclosed. The surface preferably has a regular unbiased variance of less than approximately 300 microns and preferably less than 200 microns.

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 for producing concrete products provided with inlaid patterns includes (a) preparing a reusable mold provided with recessed patterns by applying ultra violet rays on the surface of an ultra-violet-ray setting resin plate, (b) preparing a waste mold provided with recessed patterns from the reusable mold, the waste mold being made of a soluble material which can be dissolved by water, solution or heat, (c) casting concrete into the waste mold and solidifying the concrete to provide a concrete block on the waste mold, (d) dissolving and removing the waste mold from the concrete block and providing recessed patterns on the surface of the concrete block, (e) filling a coloring material into the recessed patterns on the surface of the concrete block and solidifying the coloring material, and (f) grinding the surface of the concrete block to produce concrete products provided with inlaid patterns on the surface thereof.

Abstract: The design process for a motor vehicle component part by making drawings of cross sections of the part at spaced intervals along the surface. Cardboard templates are cut to the cross sectional shape of the inside of the part, and mounted on a rigid base at the same spaced intervals as the spaced intervals of the cross sections of the drawings to define a skeletal frame. A sheet material such as cardboard is adhesively bonded to the skeletal frame, to define a rough model of the part. This rough model is then layered with glass fiber and bonding resin and finished to the desired outside finished surface dimension shown on the drawing. This provides a finished model of the part, or the glass fibers and bonding resin build up may be removed from the cardboard to be a prototype part. Furthermore, the model may be used to make a mold from which a number of prototype parts may be made.

Abstract: Disclosed is a continuous process for replicating interference patterns in radiation curable coating compositions or materials. Radiation curable coatings are brought into contact with interference patterns borne on the surface of an endless belt or revolving drum. The curable coating which may be supported by a substrate or unsupported is irradiated to cure it at least sufficiently so that it can be stripped from the replicating surface.

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 making precision low cost molds by applying a plurality of layers of material to a pattern. The method includes providing a pattern of the part to be formed; orienting the pattern on a surface plate in a molding dam; applying a release coating to the surfaces; applying a thin resin layer to form the mold surface; applying a layer of fiber reinforced tooling resin to the thin resin layer; applying an epoxy-dry plaster bonding layer to the tooling resin; inserting a reinforcement framework into the dam; and applying bulk casting plaster to complete the body of the mold.

Abstract: A process for the reproduction of works of art made of a lithoid material including the use of a silicone rubber to obtain a negative mold of the work of art, wherein a thin layer of a fluorinated grease, based on polytetrafluoroethylene and a liquid perfluoropolyether, is first applied to the work of art.

Abstract: A cast article having a complicated shape of the appearance and the hollow can be obtained by forming a coating film on the surface of a pattern from a solvent-insoluble material to prepare a mold pattern, filling and hardening a molding material around the mold pattern, dissolving the pattern with a solvent, and removing the residue of dissolution and the coating film outside the mold.

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 casting die, for forming a segmented mirror, is formed by the steps including:providing a negative or positive casting of the desired continuous surface shape;cutting the casting into small segments to form non-circular gaps between segment cross-sections;translating the segments relative to one another in a common direction to contact a shaping surface or surfaces, while maintaining constant gap widths between the segments;joining the segments to form a unitary body by adding filler material to the gaps.

Abstract: A reinforced concrete wall, such as a road barrier or barricade, has a monolithic surface ornamentation thereon constituted by pigmented cements and grooves simulating mortar joints. In the horizontally oriented top portions of the wall where the pigmented cements are substantially thicker than the layers of pigmented cements monolithically joined to the vertical oriented portions of the wall so that these portions, which are subject to chipping and the like during handling and use will retain their aesthetically pleasing appearance. In the molding process, ribs on the mold surface which will form the grooves have a retardant applied thereto so that the cement forming the mortar joint will set at a slower rate than the rest of the body of the concrete wall and when removed from the mold can be brushed. When the wall is in the form of a road barrier, the ends are provided with a conical projection and a conical recess, respectively, to provide coupling between adjacent wall units.

Abstract: A method of manufacturing surface relief holograms wherein an original surface relief hologram in the form of an endless loop or a drum is continuously coated with a radiation-curable resin. After curing, the resin bears a replica of the original hologram and it is continuously drawn off from the original as a sheet or film. The replica film becomes a hot-stamping foil when formed in contact with a carrier film, metallized, and coated with a hot-stamping adhesive.

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.

Abstract: Processes for manufacturing substrates of mirrors of resin concrete and the corresponding mirrors. A process for manufacturing a mirror substrate including the following operations: (1) a mould is manufactured of which the bottom has a polished upper face, complementary of the reflecting face to be made; (2) the polished face is coated with a film of a demoulding product and a hard, uniform layer is deposited; and (3) a resin concrete is cast into the mould and it is left to harden and then demoulding is effected in order to obtain a substrate of resin concrete. This process is used in the mass-production of substrates of mirrors and of mirrors of astronomical quality.

Abstract: A process for fabricating graphite/epoxy tools where graphite/epoxy lamin is laid up on a mandrel to form an oversized shell which is subsequently machined to conform to the design dimensions.

Abstract: An investment casting process employs a low-cost plastic pattern manufactured by machining. A mold is cast around the plastic pattern following which the pattern is removed from the mold to leave a mold cavity which molten metal or the like may be poured to produce a finished part. Reusable plastic patterns may be formed by casing silastic rubber. The silastic rubber patterns may be mechanically separated from the mold without damaging the pattern.

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: 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 print is made of the sole of a foot in a block (1) of modelling clay. If necessary the print is corrected for orthopedic reasons. A rigid shape (23) is cast in the print, and after unmolding, the contour (26) of a sole to be made is marked on the shape in relief. The shape is then used to mark said contour in hollow form in the footprint. The block is then cut through along said contour and the central portion of the block is removed. The rigid shape is reinserted in the remaining peripheral portion of the footprint, and a sole is cast inside the peripheral portion and on the rigid shape. A first sole may be made in a single session in the presence of the patient. Thereafter, the rigid shape may be conserved, and used to make any subsequent soles that may be necessary without requiring the patient to be present.

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 forming a resinous embossing plate adapted for use in an embossing and diecutting press for embossing a design onto paper greeting cards. The method comprises providing a line sketch of a design, making a photographic negative of the line sketch, and using the negative to apply the line sketch to both sides of a thin sheet of soft embossable material. Manual indenting of the design into the embossable sheet to provide a female matrix on one side of the embossable sheet. The embossed sheet is then reversed, so that the male portion of the matrix design faces upwardly, and disposed in a mold enclosure. Liquid plastic and fibrous reinforcing material is added to form a relatively low cost embossing plate. Plastic negative of the embossing plate is used in the press in conjunction with the embossing plate, for embossing the design onto the paper greeting card stock.

Abstract: Method for producing a separating nozzle element including a separating body and terminal plates, for the separation of a gaseous or vaporous mixture, wherein the separating body comprises separating structures which penetrate the separating body and define separating chambers and gas conduits, and the terminal plates are provided with channels for the intake and discharge of gas streams. A mold layer is produced which contains negative outlines of the separating structures. Thereafter, the negative outlines of the mold layer are filled with a structure material which is compatible with the gaseous or vaporous mixture to be separated to form the separating structures. The mold layer containing the negative outlines of the separating structure is produced by shaping the mold layer from a reusable tool provided with the positive outlines of the separating structures.

Abstract: A mould part which is intended to be brought together with at least one other mould part, to form a closed mould cavity in which plastics objects can be shaped. The mould part comprises a composite mould body which includes a support section (10) made of rigid material and having a surface whose shape corresponds to the shape of the object to be formed, and a mould shell (2,3,4) which is detachably arranged on said surface and which is suitably made from a plastics material having an extremely fine surface which serves as the moulding surface. The mould shell can be readily replaced, at low cost, with a new mould shell, after having been in use for a given length of time. The invention also relates to a method for manufacturing mould parts in accordance with the above, and to the use of such mould parts.

Abstract: A method for preparing a female mold employing a thermoplastic resin sheet which is softenable and moldable at a relatively low temperature and hardenable at a room temperature. This female mold is accurately profiled by a head of a person who will wear a wig and advantageously employable as a female mold for forming a head model or male mold used for a wig base or used as a workbench for the wig.

Abstract: A metal film is deposited on a photoresist layer having information-dependent pits, and a first film of low surface energy is deposited on the metal film to thereby provide a master for making a stamper blank. A layer of radiation curing resin is deposited on the first film of low surface energy, and then a transparent plate of acrylic resin is placed on the layer of radiation curing resin, which is hardened by exposure to radiation such as ultraviolet radiation through the transparent plate. The transparent plate and the hardened layer are separated as a unitary stamper blank from the master. A second film of low surface energy is then deposited on the stamper blank to form a stamper. The first and second films of low surface energy are made of polymerized octafluorobutane and serve to allow the stamper blank and information storage discs to be released clear of the master and stamper, respectively.