Abstract: A method for manufacturing molded products of thermoplastic material by injection molding or extrusion molding a material containing a thermoplastic material as a primary component and a second polymer or a blend of the thermoplastic material and second polymer as a primary component and an inorganic material. The material is molded under the following mold conditions by a general type or vent type molding machine. The material is provided with a water content of less than about 1% by weight. The wall temperatures of the molding cylinder are controlled at different locations of the molding machine. The residence time of the molding material in the cylinder is controlled in response to the cylinder temperature so that the residence time is reduced as the temperature is increased whereby the residence time of said material in the cylinder is less than about 23 minutes. The temperatures of the discharge end is maintained within the range of plus 35.degree. C. or minus 25.degree. C.

Abstract: The invention is a process for the production of solid aromatic polyamic acid and polyimide fibers from a wet gel or coagulation bath wet get using N,N-dimethylacetamide (DMAc) solutions of the polyamic acid derived from aromatic dianhydrides such as 3,3',4,4'-benzophenonetetracarboxylic dianhydride (BTDA) and aromatic diamines such as 4,4'-oxydianiline (4,4'-ODA). By utilizing the interrelationship between coagulation medium and concentration, resin inherent viscosity, resin % solids, filament diameter, and fiber void content, it is possible to make improved polyamic acid fibers. Solid polyimide fibers, obtained by the thermal cyclization of the polyamic acid precursor, have increased tensile properties compared to fibers containing macropores from the same resin system.

Abstract: An orthotic footwear insert is made of a resilient shock-absorbing layer. The layer has an upper surface, intended to receive the heel, the upper surface having a plurality of outwardly projecting nodules arranged in a waffle-like pattern which defines the upper plane. The layer also has a lower surface, beneath the heel-receiving surface. The lower surface has a plurality of rib members extending longitudinally between the back and front edges and generally parallel to the side edges of the layer. The rib members are therefore arranged such that air does not become trapped between them when pressure is applied to the layer. The invention also includes a method of making a shock-absorbing composition, which can be used to construct the footwear insert or other products. According to this method, an elastomeric material is comminuted into particles, and the resulting composition is formed into a desired shape. Preferably, a quantity of water is added to the composition.

Abstract: The present invention contemplates a stereolithographic apparatus and method having a liquid organic phase and a fluid phase separated by a membrane that inhibits contact between the phases.

Abstract: A polyurethane covered golf ball is made by allowing the polyurethane cover stock material to partially cure in an open mold and subsequently molding a golf ball product. The molding is done by first molding a smooth-surfaced golf ball product in a smooth-walled fixed-pin mold and then, in a second molding step, using a compression mold to impart dimples onto the smooth-surfaced golf ball product. Between the two molding steps an intermediate curing step is employed. The initial curing time is an open mold and the intermediate curing time between the two molding steps is minimized through the use of a sufficient amount of catalyst, by keeping the smooth mold at an elevated temperature, or by using the fast-reacting chemical components.

Abstract: Process for forming tubular microstructures having predetermined shape and dimension from surfactants comprising the steps of selecting a lipid which self-aggregates into a tubular microstructure; selecting a lipid solvating organic solvent in which tubules may form; removing trace water from the selected organic solvent; dissolving the selected lipid in the dried organic solvent; allowing the dissolved lipid to grow into tubular microstructures in the dried organic solvent for a selected period of time and at a temperature below the melting point of the selected lipid.

Abstract: A process for producing polyethylene materials in which ultrahigh molecular polyethylene is molded by compression, extrusion or rolling and stretching in a solid phase and at specified temperatures. The polymer is formed by a selected multi-stage polymerization with the use of a composite catalyst of specified compositions. Fibers or films are obtained with improved strength and modulus qualities.

Abstract: A method for manufacturing capsules causes the solution of thermo-gelling material to gelatinize once, and then drys the gel. Therefore the process of manufacturing capsules is less affected by drying conditions, thus providing capsules of uniform wall thickness without wrinkle. In the apparatus, circulating capsule pins are dipped in the solution of thermo-gelling material, thus the solution adheres to the pins. The pins are rotated upside down, thus thickness of the solution adhering to the pins becoming uniform. Then the pins are retained in the vessel maintained at a higher temperature than the gelling temperature of the solution, and the solution adhering to the pins is gelatinized. The thus-formed gel is dried through a drying device, and the dried gel, i.e. capsules, is removed from capsule pins.

Abstract: A method for producing a resin-bonded magnet, which includes steps of mixing a magnet element and microcapsules each of which contains at least one component of a thermally polymerizable resin composition as a binder component, mechanically breaking at least a part of the microcapsules during formation of a green compact comprising said resin composition and said magnet element to discharge the components of said resin composition from the capsules, and curing said resin to produce the resin-bonded magnet.

Abstract: A method is shown for forming a wiper blade in which a continuous length of elastomer is extruded through a die having a die opening shaped to produce a pair of wiper blades joined in edge-to-edge relation. The elastomer is preformed to produce a weakened mid- section and then cured. The cured elastomer is then separated into two separate lengths of wiper blade by pulling the length of continuous elastomer along the weakened mid-section.

Abstract: A device fabrication method is disclosed in which a precursor polymeric or oligomeric material, capable of undergoing a curing reaction involving crosslinking and/or imidization, is at least partially cured and incorporated into the device being fabricated. Significantly, the at least partial curing is achieved by heating the material at generally increasing (although not necessarily continuously increasing) temperatures. In addition, the heat is supplied at a rate so that the temperature of the material is always maintained at or below the corresponding glass transition temperature of the material, which increases during the heating process.

Abstract: A process for preparing aromatic polyamide film wherein an aromatic diamine and an aromatic diacidchloride are dissolved in an amide polymerization solvent containing an inorganic salt, a partial polymerization is effected at a low temperature to form an optically anisotropic liquid crystalline prepolymer dope, continuously extruding through a film die under a draw ratio or subjecting to a shear and contacting the prepolymer with a second solvent which is a polymerization accelerating-precipitation solvent to obtain an aromatic polyamide film free of crystal defect layer perpendicular to the film axis and having high strength and a high degree of molecular orientation.

Abstract: The present invention relates to a process of forming an electromagnetic shielding gasket by forming a core of elastomeric material, coating the core with bands of an electrically conductive textile material, passing the coating core through a die to calibrate the coated core, heating the coated core to cure the elastomeric material and winding up the cured core.

Abstract: Thin-walled catheters are provided which have an elongated fuseless polymeric tube that is made from a single tube of extruded polymer. The elongated fuseless polymeric tube includes a body portion that had been subjected to a high temperature zone in order to solid state polymerize and enhance the mechanical stability, burst strength and kink resistance of the body portion. Also included is a tip portion of the elongated fuseless polymeric tube which was subjected to a low temperature zone to retain the initial properties of extruded polymer.

Abstract: A process for the production of polyester polyurethane elastomeric fibers having improved humid aging resistance which comprises the steps of reacting a polyester diol with an excess molar amount of an organic diisocyanate to prepare a urethane prepolymer having terminal isocyanate group at both ends thereof; extending the chain of the prepolymer with a bifunctional active hydrogen compound and 0.5 to 10.0 mole % of a diaminosilyl compound based on the total amount of the bifunctional active hydrogen compound during or after preparation of the prepolymer to obtain a polyurethane; spinning the polyurethane into fiber; and crosslinking the polyurethane during or after spinning.

Abstract: Focusing radiation on a patterned area of a substrate upon which flowable radiation curable material is being deposited causes a dam of cured material to form which restricts the flow of the material into areas which are to remain free of material.

Abstract: A process and apparatus are provided for producing polymerized plugs in which the polymerization starting materials are passed through heated reaction tubes by gravity feed. The polymerized rods so produced are cut into plugs and packaged for use. In an alternative embodiment, the polymerization starting materials are first encased within flexible sleeves, and the flexible sleeves are then passed through the heated tubes by gravity feed to form polymerized rods. Apparatus for performing the process includes at least one tube having an inlet opening and an outlet opening, the outlet opening being at a lower elevation than the inlet opening to provide for gravity feed through the tube, and structure to heat the tube. A cutting device cuts the polymerized rods into plugs as they exit the outlet opening.

Abstract: Large fittings or other structures are made by rotationally moulding a first component 18 of polyethylene and joining cylindrical pups 20, 22, 24 of polyethylene to the component by butt fusion joints 26, 28, 30. The structure within the boundary 50 is irradiated with gamma radiation followed by post-heating to remove free radicals. The extremities of the pups are shielded to prevent irradiation. Their capability to be joined to polyethylene pipes 12, 14, 16 by butt-fusion joints 32, 34, 36 is unimpaired. The irradiation introduces cross-linking to give improved properties such as impact resistance and stress crack resistance and to bring the fitting within the specification for polyethylene pipe for natural gas distribution. The joints 26, 28, 30 are made using differential heating of the ends to be joined to compensate for differences in melt flow index. Alternatively, the component 18 is slightly irradiated to lower its MFI before the pups are joined to it.

Abstract: A process is disclosed for producing a composite hose constructed with a core tube, a reinforcement layer and a cover laminated one on another, the core being made up of a resin inner wall and a rubber outer wall. Gas impermeability and flexibility are enhanced by formation of the inner wall on a mandrel of selected synthetic material and specified bending strength.

Abstract: A mechanically stable, conformable collagen wound dressing sheet material is fabricated by lyophilizing (freeze-drying) a collagen composition and compressing the porous pad thus produced at a pressure between about 15,000-30,000 p.s.i. The sheet material thus produced may also be treated with optional dehydrothermal crosslinking known in the art. In addition to mechanical stability and conformability, the sheet material demonstrates high absorptivity, i.e., about 15-20 times its weight in isotonic saline, making it highly useful as a medical or surgical dressing or as a carrier for other medicaments such as antibiotics. The sheet material may be impregnated with thrombin.

Abstract: A composite porous membrane is formed from a porous polymeric membrane having desired bulk properties on which is directly coated a cross-linked polymer having desired surface properties. The composite membrane retains the porosity of the porous polymeric membrane. The cross-linked surface polymer is produced from a crosslinkable monomer or polymer by energy from an electron beam in the absence of a chemical polymerization initiator.

Abstract: A stereolithographic method which employs an ultraviolet-curable liquid composition adapted to cure rapidly to a lightly cross-linked solvent-swellable three-dimensional complexly-shaped polymeric thin-walled element constituted by heat-softenable solid polymer upon exposure to ultraviolet dosage in the range of about 0.1 to about 10 Joules per square centimeter and which possesses reduced distortion comprises, from 20 to 80 weight percent, of a resinous polyacrylate or polymethacrylate dissolved in a combination of 10 to 45 weight percent of a liquid polyacrylate or polymethacrylate, which is preferably trifunctional, and 10 to 45 weight percent of liquid N-vinyl monomer, preferably N-vinyl pyrrolidone. Thus, the weight ratio of polyacrylate: polymethacrylate: N-vinyl monomer is about 1:2:2 to about 8:1:1. One of the foregoing polyacrylates or polymethacrylates is a polyacrylate and the other is a polymethacrylate so that good cure speed is accompanied by good distortion resistance.

Abstract: Disclosed is a process for the preparation of a composite including a room temperature vulcanizing silicone rubber and a chemically resistant polyester film which may be polyethylene terephthalate. The composite has particular utility as a part of medical equipment, for example as a component in an ultrasonic transducer. The susceptibility of the composite bond so formed to chemical challenge in the user environment is reduced or eliminated.

Abstract: A mandrel suitable for use in the production of a rubber hose formed from a composition comprising:(i) at least one member selected from the group consisting of(A) an ethylene-alpha-olefin random copolymer having an ethylene content of 10 to 95 mol % and a degree of crystallinity, based on X-ray determination, of 0 to 20%,(B) a propylene - C.sub.4 to C.sub.10 alpha-olefin random copolymer having a propylene content of 50 to 80 mol % and a crystal fusion heat amount, determined by a differential scanning calorimeter, of 0 to 80 Joule/g, and(C) an oligomer having the general formula: ##STR1## wherein n and p are independently zero or an integer, m is zero or 1, and R is ##STR2## and (ii) 98% to 30% by weight of a 4-methyl-1-pentene polymer, wherein the weight ratio of the component (i) to the component (ii) is from 2:98 to 70:30.This mandrel has excellent dimensional stability, durability, heat resistance, and releasability.

Abstract: Disclosed is a process for producing a surgical sponge which contains contrast agent embedded in a polymer matrix in proportions of up to 70 wt. %. The matrix consists of a polymer material free of plasticizers. In the process for the production of the sponge a matrix for the contrast agent is used, which is an uncrosslinked, viscous liquid, prepolymer state until after it has been extruded onto the basic fleece material, and not until a process step that then follows is the polymerization completed.

Abstract: Methods for preparing highly conductive, oriented polymers are disclosed. In the preferred embodiment, solution of conductive polymer is cast onto the surface of a stretchable support material, and oriented polymer is produced by removing solvent from the solution and stretching the support material. The invention is particularly useful for preparing oriented films of polyaniline which films have been shown to exhibit conductivities in the range of 300-2500 S/cm.

Abstract: A process is disclosed for making an oriented polymer label product which includes:(a) applying a solventless, curable silicone release composition to an extrudable, orientable polymer;(b) extruding the polymer as a sheet or film;(c) orienting the sheet or film such that curable silicone release composition migrates to at least one surface of the sheet or film forming a substantially continuous layer thereon; and(d) subjecting the oriented sheet or film to silicone-curing conditions whereby said curable silicone release composition forms a peelable release layer thereon.

Abstract: A method for making removable, reusable adhesive products from soft, solvent-free rubber compositions is disclosed. The rubber compositions are packed together by molding them into thin coatings between a release film and a porous substrate to allow curing. The resultant product has highly desirable bonding and release properties on smooth and porous surfaces. Product applications included are automotive windshield covers, home window insulation curtains, photograph mounting boards, and indoor sign-making backgrounds.

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: An extrusion molding silicon rubber composition including (A) 100 pbw of an organopolysiloxane, (B) 5-500 pbw of finely divided silica filler, (C) 1-50 pbw of powder boron nitride having a mean particle size of up to 20 .mu.m, and (D) a curing catalyst is extrusion molded and cured into an insulating article which has improved physical properties and dielectric strength and is thus suitable as electrical insulation.

Abstract: In the process for the manufacture of a polyamide composite material reinforced with long fibers, the improvement comprising impregnating the fibers with a polyamide oligomer or prepolymer, heat-treating the impregnated fiber to increase the length of the polymer chain, and then shaping the impregnated fiber by pultrusion.

Abstract: A scratch resistant coating is applied to one or both surfaces of an extruded thermoplastic synthetic resin web by passing the web through a polishing roll stack wherein at least one of the rolls has thereon a film of a material forming such a scratch resistant coating, the coating being in this way transferred from the roll to the surface of the web.

Abstract: Production of a bonded magnet from a composition of a cross-linkable organic material and a particulate magnetic material by(1) placing in a mold a shaped composition in which the particles of magnetic material are optionally aligned and demagnetized,(2) rotating the mold about an axis thereof,(3) cross-linking the organic material in the shaped composition while rotating the mold,(4) recovering from the mold a shaped article, and(5) optionally remagnetizing the particles.

Abstract: A process by which polyester resin having extremely high molecular weight can be prepared utilizing a very rapid solid state polymerization process comprises: (1) dissolving a polyester prepolymer in a suitable organic solvent; (2) recovering the polyester prepolymer from the organic solvent to produce a porous, fibrous mass of the polyester prepolymer; and (3) solid state polymerizing the porous, fibrous mass at an elevated temperature to produce the ultra-high molecular weight polyester resin.

Abstract: Process for producing polyester fibers of high tenacity and high modulus, by melt-spinning a polyester having an intrinsic viscosity of not lower than 0.3, to obtain extruded filaments of low orientation having a birefringence not higher than 10.0.times.10.sup.-3, post-polymerizing the filaments in a heating medium, and subjecting the filaments to multi-stage drawing in at least two stages.

Abstract: An electrically semi-conducting, strippable coating material for electric wires and cables is produced by intimately mixing a premix of a polyolefin with an unsaturated organic silane, a free-radical-forming organic compound and optionally plastics additives in a hot state, until the unsaturated organic silane has reacted significantly with the polyolefin and/or the copolymerizate of olefins, preferably for 1/2-30 min. at 180.degree.-230.degree. C., and subsequently admixing comminuted carbon while the mixture is still hot.

Abstract: A plurality of abrasive sleeves (3) surround a wire rope (2) and are spaced at predetermined intervals longitudinally of the wire rope. An elastic material (4) of rubber such as natural rubber is formed between the abrasive sleeves in such a manner as to surround the wire rope. A rubber/metal bonding agent (7) such as chlorinated rubber type bonding agent is used to effect vulcanization bonding between the opposite end surfaces of each abrasive sleeve and the elastic material and between the wire rope and the elastic material. The ends (19) of the wire rope are connected together by a combination of end connecting members (5, 6a) provided with male threads (17, 17a) and fixed to the ends of the wire rope and on internally threaded connecting sleeve (30), whereby a closed loop is formed.

Abstract: A method is shown for forming a wiper blade in which a continuous length of elastomer is extruded through a die having a die opening shaped to produce a pair of wiper blades joined in edge-to-edge relation. The elastomer is scored in the mid-section thereof to produce a score line and then cured. The scored and cured elastomer is then separated into two separate lengths of wiper blade by dividing the length of continuous elastomer along the score line.

Abstract: If ultra-high-molecular-weight polyethylene having an intrinsic viscosity (.beta.) of at least 5 dl/g is grafted with a silane compound in the presence of a radical initiator and extrusion-molded and the extrudate is impregnated with a silanol condensation catalyst after or during drawing and is then exposed to water to effect crosslinking, there is obtained a novel molecularly oriented molded article in which increase of the melting temperature, which is not observed in conventional drawmolded or crosslinked molded articles of polyethylene, can be attained, and even if this molecularly oriented molded article is exposed to a temperature of 180.degree. C. for 10 minutes, the molded article is not fused but the shape is retained and even after this heat history, a high strength retention ratio can be maintained.

Abstract: Polyvinyl butyral (PVB) resin lightly cross-linked through stable intermolecular linkages developed, for example, through use of a dialdehyde or trialdehyde, to selectively increase PVB molecular weight and the modulus of a plasticized sheet formed therefrom intended for use in laminated safety glass assemblies.

Abstract: A method of preparing a glass fiber-reinforced, crosslinked polymer structure which comprises saturating an uncoated, unsized woven glass fabric with a polymerizable liquid comprised of dicyclopentadiene and, optionally, one or more other metathesis polymerizable strained ring polycyclic cycloolefins, subjecting said saturated fabric to polymerization conditions, and, thereafter, post-curing the resultant structure at a temperature greater than about 225.degree. C., and a glass fiber-reinforced, crosslinked polymer prepared by that process, are disclosed. Post-curing at temperatures greater than 225.degree. C. enhances the physical properties of the woven fiber-reinforced, crosslinked polymer.

Abstract: A method of vulcanizing a tubular article by extruding a sheath of unoriented polyethylene terephthalate about the article followed by quenching the sheath to an amorphous state. The sheathed article is then subjected to vulcanizing conditions in order to convert the sheath from the low density amorphous state to the higher density crystalline state, thus compressing the article to effect a smooth finish.

Abstract: In order to manufacture sealing gaskets for receptacles containing aggressive chemical substances, one known technique consists in coating a film of PTFE or other plastic material onto rubber. However, in the past, it has been possible to ensure that the film adheres adequately to the rubber only by making use of an intermediate glue. The present method causes a film of PTFE to adhere directly on a sheet of rubber by treating one of the faces of the PTFE film by the corona effect and then rolling the treated film against the rubber while still raw and vulcanizing the resulting laminated structure.

Abstract: A method for producing an optical disk base to store, record, and retrieve sounds, images, and information. An improved method for producing an optical disk base includes the steps of injecting a photo-curable resin into a cavity, curing the photo-curable resin by irradiation with light, and demolding, where the photo-curable resin is injected from an injection nozzle having an outside diameter which is substantially equal to the diameter of the center hole of the optical disk base and also having a horn-shaped opening at the forward end. The injection nozzle is arranged at the center of the optical disk base. The forward end of the nozzle is closed after injection and the photo-curable resin is irradiated with light, with the injection nozzle projected into the cavity. A liquid resin is injected in the form of uniform flow without entrapped bubbles, so that the anamolous molecular orientation is avoided and the contamination with insufficiently cured or uncured resin is also avoided.

Abstract: By compressing and heat curing a non-resilient, non-flexible recurable material formed by subjecting cured polyimide foam to the action of pressurized steam, a wide variety of useful articles may be produced. These include tough, flame-resistant plastic films, sheets, panels, boards, and shapes in general; composites (both reinforced and unreinforced); and laminates and other articles in which separate shapes or parts are bonded together by a new type of tough, flame-resistant adhesive. Additionally, heretofore worthless waste products such as the kerf cut away from buns of polyimide foam during the foam manufacturing process can be converted and vastly upgraded into any of such an array of new articles of manufacture such as those just mentioned.

Abstract: A method for molding ceramic powders comprises forming a slurry mixture including ceramic powder, a dispersant for the metal-containing powder, and a monomer solution. The monomer solution includes at least one multifunctional monomer, a free-radical initiator, and an organic solvent. The slurry mixture is transferred to a mold, and the mold containing the slurry mixture is heated to polymerize and crosslink the monomer and form a firm polymer-solvent gel matrix. The solid product may be removed from the mold and heated to first remove the solvent and subsequently remove the polymer, whereafter the product may be sintered.

Abstract: A method of forming hollow, porous elastomeric bodies and hollow, duo-layered elastomeric bodies wherein one layer is porous and contiguous with the other layer which is solid by (a) coating a surface of a mandrel with a coating liquid, (b) adhering a layer of water-elutable particles onto the coated mandrel surface, (c) applying a layer of fluid elastomer composition to the particle-coated mandrel surface wherein the elastomeric composition is capable of forming a water-insoluble elastomer, (d) causing said elastomeric composition to form a cohesive mass while in contact with the particle-coated mandrel surface, (e) dissolving said elutable particles from the cohesvie mass with a water-based solvent, and (f) removing the cohesive mass from the mandrel. The coating liquid comprises water and may also further comprise a wetting agent and/or a sugar. The invention also relates to the method wherein the water-elutable particles are adhered to the mandrel surface by heating the mandrel surface.

Abstract: A process for making a multilayered formable plastic composite laminate and a process for its manufacture which includes preparing an acrylic composition which includes the reaction product of a mixture of predominantly an acrylic monomer and a substantially lesser amount of a polymer thereof, at least one free radical reaction initiating reaction catalyst, and optionally, a chain length regulating agent or a cross-linking agent; deaerating the acrylic composition; casting the deaerated acrylic composition upon a sheet or laminate of a thermoplastic material; and curing the cast acrylic composition in several successive stages so as to substantially polymerize the acrylic monomer and to permit penetration of the acrylic composition preferably to a depth of between about 0.001-0.

Abstract: A fiber/resin composite whose resin phase is formed by at least initial actinic radiation curing of a resin composition comprising an actinic radiation curable first resin component and a second resin component which is non-cured under curing conditions effective for the first resin component. The actinic radiation exposure of the fiber/resin composition effects curing of the first resin component to immobilize the composite and impart structural integrity thereto, whereby the composite may be handled, packaged, or further processed. Filament wound, braided, and pultruded articles are described, together with associated methods for forming such articles by filament winding, braiding and pultrusion. As a specific embodiment, a solid fuel rocket motor is disclosed comprising a solid fuel body in a filament wound fiber-resin composite casing formed by filament winding of the solid fuel body with resin-impregnated filament or rovings thereof.

Abstract: The specification describes and claims a method of making therapeutic rings from a curable silicone rubber based composition. The rings are capable of controlled release of the therapeutic agent in the human or animal body. The method includes the steps of:(i) extruding a first composition comprising a therapeutic agent and a first elastomer-forming silicone composition to provide a core;(ii) extruding a second composition comprising a second elastomer-forming silicone composition to provide a sheath enclosing the core;(iii) bringing together end portions of a piece of extruded core and sheath to form a ring,(iv) effecting crosslinking of the extruded core, and(v) effecting crosslinking of the extruded sheath.