Abstract: According to one embodiment of the invention, a system for curing a composite material includes an oven having an inner wall defining an inner chamber, an outer wall defining an outer chamber between the inner wall and the outer wall, a hot air distribution manifold disposed within the inner chamber, a cold air distribution manifold disposed within the outer chamber, and an exhaust chimney having a cold air distribution conduit disposed therein coupled to the outer chamber. The system further includes a hot air supply system coupled to the hot air distribution manifold of the oven that is operable to supply hot air to the hot air distribution manifold, a cold air supply system coupled to the cold air distribution manifold and the cold air distribution conduit that is operable to supply cold air to them, and a plurality of hot air exhaust passages formed in the inner wall of the oven. The hot air exhaust passages are adapted to transport hot air within the inner chamber to the outer chamber.

Abstract: A method for making freeform-fabricated core composite articles using freeform-fabricated machine. The articles are capable of being utilized as end products rather than prototype models by creating a core having an interior structure to provide strength to the core and to enhance the strength to weight ratio of the article.

Abstract: A manufacturing method for obtaining a rubber thread by (a) feeding a rubber composition (8) between a heat roller (3) and a belt (7) pressed against the heat roller (3) and pressurizing and crosslinking the rubber composition (8) by means of the heat roller (3) and the belt (7), thereby obtaining a crosslinked sheet material, and (b) cutting the crosslinked sheet material to obtain the rubber thread. A pressure to be applied to the rubber composition (8) at the crosslinking step is 0.03 Mpa to 1 Mpa. The rubber composition (8) fed at the crosslinking step is previously formed into a sheet by extrusion. Since a dry blend method is employed for the manufacturing method, a great workability can be obtained. The rubber thread obtained by the manufacturing method is easily stretched and is broken with difficulty during the stretch.

Abstract: The invention relates to a method of producing a high-tension insulator comprising an elongated central solid or hollow body (1), a synthetic material shield layer (6) and one or more synthetic material weathersheds (3) by the following steps:

Abstract: A method of assembling a coil includes forming a ferrite core having a top end, a bottom end, an inner opening extending from the top end to the bottom end, a cylindrical outer surface, and a step portion formed near the bottom end, the step portion extending past the outer surface. A first high dielectric material is applied on the outer surface of the ferrite core, then a conductive wire is wound onto the high dielectric material, whereafter a second high dielectric material is applied over the conductive wire.

Abstract: The present invention relates to the prevention and decrease of osteolysis produced by wear of the ultrahigh molecular weight polyethylene (UHMWPE). Methods are disclosed for the isolation of wear particles, preparation of implants exhibiting decreased wear in comparison to conventional UHMWPE and preparation of implants that cause decreased biological response in comparison to conventional UHMWPE. The implants created by these methods are also included in the present invention.

Abstract: The present invention refers to a package for containing and displaying cosmetic products and to a process for manufacturing the same. The package comprises a component (5) suitable to contain at least one cosmetic product (4). Said component (5) is made of a material that is poured and left to harden.

Abstract: A stereolithographically fabricated marking for a semiconductor device component, such as a packaged or unpackaged semiconductor device or another substrate. When formed on a semiconductor device with a stereolithographically formed package structure, the marking may be integral with the package. The marking may be formed as apertures through or recesses in one or more stereolithographically fabricated layers of material, or the marking may include one or more stereolithographically fabricated layers that protrude from a surface of a semiconductor device component. Raised markings may also be formed on the surfaces of packaged or bare semiconductor device components. Alternatively, the marking may be fabricated separately from a semiconductor device component, then secured thereto. Methods for stereolithographically marking semiconductor device components are also disclosed.

Abstract: The present invention relates to novel polymeric compositions that exhibit Reverse Thermal Gelation (RTG) properties for use as Support Materials (SM) in the manufacture of three-dimensional objects. These polymers are Temperature Sensitive Polymers that respond with a significant change of properties to a small change in temperature. Temperature Sensitive Polymers exhibit cloud point (CP) or lower critical solution temperature (LCST) in aqueous solutions. Water-soluble Temperature Sensitive Polymers are chosen to give low viscosity liquid at low temperature when dissolved in water and by that to permit easy dispensing at low temperature. Raising the temperature above their gelation temperature (Tgel) will result in solidification of the composition. At its gel position the material has favorable characteristics as a support and building material. The gel layers have the appropriate toughness and dimensional stability to support the model layers during the building process.

Abstract: Pore-free rubber articles are prepared by dip-molding in a dipping medium that includes a vulcanizing agent, then by immersing the dip former in a heated liquid bath that is chemically inert. A particularly effective liquid bath is molten inorganic salt. In addition, the tensile properties of an article of vulcanized rubber can be improved to an unusually effective degree by immersing the already vulcanized article in a solution of a vulcanizing agent to cause the rubber of the article to absorb or imbibe the vulcanizing agent from the solution, and then immersing the rubber and the imbibed vulcanizing agent in a heated liquid bath to increase the degree of vulcanization.

Abstract: This invention is concerned with a method for producing water-insoluble polysaccharides. A method for making the water-insoluble bio-compatible gel includes activating the hydroxyl-containing polysaccharides with the activating agent to form activated polysaccharides, and cross-linking the activated polysaccharides, under moderate conditions producing different shapes of the water-insoluble bio-compatible gel. The water-insoluble bio-compatible gels, films, porosities, powders, sheets, fibers and spheres of this invention may be applied to various medical and cosmetic uses.

Abstract: The invention provides non-stick coated molds, a process for the preparation thereof and their use for the production of plastics molded parts, particularly for the production of molded parts made of polyurethane foam.

Abstract: A method including synthesizing polymeric precursors via organic acid modification; fabricating a fibrous material of the polymeric precursors; and fabricating a body of the fibrous material. One body has dimensions suitable as an electrode component of an electrical storage device.

Abstract: The cure rate of phenol-aldehyde resins is accelerated by conjoint use of a cyclic carbonate cure accelerant and an amine cure accelerant. The cure rate is accelerated still further by addition of a resorcinol source to resin comprising a cyclic carbonate and an amine cure accelerator. Also, cured resins made in accordance with the method.

Abstract: This invention relates to the field of optical chemical sensors which utilize indicator molecules to detect a particular analyte in a sample, wherein the indicator molecules produce a detectable response when exposed to the particular analyte to which the indicator molecule is sensitive. Specifically, this invention relates to the use of a matrix embedded within a membrane, where the matrix enhances the scattering of light and serves as a support which provides superior mechanical strength. The invention also relates to methods of using the improved sensor in conjunction with fiber optic probes.

Abstract: A polishing pad used in a method for polishing a semiconductor device is made by combining a polymeric matrix and a dissolvable substance that dissolves upon contact with a polishing slurry.

Abstract: This invention is a method of fabricating a panel of composite material. The panel includes two outside skins and stringers attached inside of the two outside skins for reinforcing the two outside skins. A plurality of stringers for reinforcing outside skins is formed from dry preformed fibers. The plurality of stringers are disposed at a predetermined interval. Adjacent two stringers is connected with each other via a connecting member made from dry preformed fibers. The connected stringers and the connecting members are set into a forming mold. Resin is introduced into the forming mold to impregnate the dry preformed fibers of the stringers and the connecting members. The resin-impregnated stringers and the resin-impregnated connecting members are cured to unite the resin-impregnated stringers and the resin-impregnated connecting member into one body of “Rudder Shape” stringer. A prepreg is laminated onto an outside-skin shaping mold.

Abstract: The present invention is directed to a method of forming a golf ball subassembly. After forming a partially-cured golf ball subassembly, the partially-cured subassembly is placed in a medium to continue curing until it is a substantially-cured subassembly. The medium in this embodiment is heated air and the subassemblies are moved through the heated air on a spiraled path. Subsequent to substantially curing the subassembly, it can be cooled in a cooling unit with a spiraled path. In one embodiment, the subassembly is a core, in another embodiment the subassembly is a core with a castable material thereabout.

Abstract: Thermoplastic elastomeric compositions and processes for preparing the compositions comprising a blend of polypropylene, styrene-ethylene butylene-styrene copolymer, ethylene-propylene-diene monomer elastomer, linear low density polyethylene, peroxide crosslinking agent and a crosslinking coagent. The peroxide crosslinking agent and crosslinking coagent provide a crosslinking system. The compositions improve melt strength and increase resistance to flow and tear. The composition may further comprise mineral oil, antioxidant, colorant, a processing aid and stabilizer and mixtures thereof. The processes for preparing thermoplastic elastomeric compositions are particularly useful in microcellular injection molding to form articles with improved surface characteristics.

Abstract: A method of forming ablative insulation coatings on aerospace structures and articles produced thereby. The method includes forming a mold having a cavity configured to complementarily receive at least a portion of the structure and directly molding the ablative coating to a surface of the structure by introducing a prepared ablative mixture, such as an epoxy resin, into the mold. The process may desirably include curing at atmospheric pressures to reduce the expense and equipment required in carrying out the process. The method of applying the ablative coating further includes features such as varying the thickness of the ablative coating from one portion of the component to another. Control of the thickness may be effected through use of spacers embedded into the ablative coating an formed of the same or similar material previously cured prior to placement in the mold.

Abstract: The present invention is directed to a method of forming a golf ball core. After compression molding a core material in a mold cavity to form a partially-cured core, the partially-cured core is removed from the mold cavity and placed in a medium to continue curing until it is substantially-cured. The method can also be used to form a golf ball by adding the step of forming a cover layer over the substantially-cured core. The present invention is also directed to a system for forming a golf ball core comprising an apparatus for making a core material, a compression mold for partially curing the core material, and a chamber for substantially curing the core material.

Abstract: A method of making a painted part out of molded thermoplastic material, the method comprising the steps consisting in:

Abstract: A high performance thermoplastic hose useful as a power steering hose, the high performance thermoplastic hose comprising a high performance engineering thermoplastic such as polyurethane and a chlorine-containing polyolefin such as chlorinated polyethylene, chlorinated polypropylene, chlorinated copolymers containing ethylene and propylene, chlorosulfonated polyethylene, chlorosulfonated polypropylene, chlorosulfonated copolymers of ethylene and propylene or mixture thereof, is disclosed. Also disclosed are a method for manufacturing the high performance thermoplastic hose, and a thermoplastic vulcanizate capable of resisting chemical attack and withstanding temperatures up to about 300° F.

Abstract: The invention relates to a process for the manufacture of a molding comprising the steps of

Abstract: A method and a system for fabricating articles made from thermoset resins using an ionic mold release agent. The invention uses a mold having a metal oxide surface with enhanced mold release characteristics. The release agent is applied internally in the resin composition or externally on the metal oxide surface. The method includes providing a mold, forming a metal oxide surface on the mold, providing an ionic release agent, providing the acid or base conjugate of the release agent at the metal oxide surface, providing a thermoset resin in the mold, and curing the resin in the mold. A method of using float glass having a SnO2 enriched surface, wherein the method includes the steps of providing an ionic release agent externally to the tin oxide surface, is also disclosed.

Abstract: An efficient process is described for making rubber tube segments, such as lathe-cut gaskets or conveyor roller covers, by cross-head extrusion of uncured rubber onto an axially aligned string of mandrels. Each mandrel in the string is separated from its two neighbors by respective spacers. The outer diameter of the extruded tube is kept within precise tolerances by making a non-contact measurement of the outer diameter at the output from the extruder and using the measured diameter to control the extrusion process. The extruded tube is cut into segments by a cutter that acts responsive to a spacer sensor and that makes the cuts between the mandrels. In one version, the extruded tube is conveyed through a curing oven by apparatus that only contacts and supports the tube adjacent ones of the spacers.

Abstract: The present invention is directed toward more durable golf ball cores and more durable golf balls. The golf balls of this invention comprise a cover and a core wherein the core may further comprise a center and one or more layers of a mantle disposed between the center and the cover. The core, the mantle or the layers of the mantle, comprise a mixture of one or more thermoset rubber materials and at least one compatible, modified, non-ionic polyolefin. The non-ionic polyolefin that is modified may be a homopolymer, copolymer, terpolymer, block copolymer or a mixture thereof that is present at about 0.5 to about 10 parts per hundred of the thermoset rubber material used in the core or core layer.

Abstract: The present invention relates to the fabrication of elastomeric replicas or stamps of surfaces from a stamp master, wherein the master has geometrical features below 100 &mgr;m. The elastomeric stamps of the present invention are prepared from injection-molded plastic stamp masters. The stamps are used to replicate the surfaces or patterns of the stamp master on a substrate using soft lithography techniques.

Abstract: A process for manufacturing floor and wall coverings that produces a product a user may adhere to any wall or floor surface. The process begins by blending selected volumes of epoxy and aggregate into a vessel. A selected portion of the blended mixture is poured into a mold of selected geometry. A first piece of interlocking screening material is positioned over the first selected portion of the blended mixture. A second selected portion of the blended mixture is poured over the first interlocking screening material. A second piece of interlocking screening material is positioned over the second selected portion of the blended mixture. A selected portion of an adhering material is embedded into the top surface of the second interlocking screening material and the second selected portion of the blended molded mixture. The mold is cured and the product is released from the mold.

Abstract: To make a seamless tube of polyimide, an amount of polyamic acid precursor to constitute the final tube is applied eveny as a solution to a cylindrical mandrel. The mandrel is rotated while a canted doctor blade smoothes the solution. The solvent is then expelled and the remaining precursor cured by heat.

Abstract: A furan polymer impregnated wood which comprises wood impregnated with a polymerizable furfural alcohol monomer solution containing at least water, stabilizers, and furfuryl alcohol, and at least one further compound selected from the group consisting of anhydrides, acids and combinations thereof is described.

Abstract: A monitoring and control system for use in curing composite materials includes a model for a workpiece being cured. The model calculates current internal states of the workpiece and predicts, based upon past and current states of the workpiece, future states of the cure process. These future states are represented as virtual inputs to the controller, which controls operation of the cure process based upon both real and virtual inputs. Cure rates are affected by both external temperatures and internal heat generated by the curing process itself. The internally generated heat is considered by the model when calculating current states and predicting future states. By projecting the cure state into the future, problems caused by high cure rates can be avoided. In addition, pressure can be optimally controlled in response to estimated internal material state.

Abstract: A detoxification process for rendering three-dimensional objects formed by solid freeform fabrication techniques biocompatible for use in long-term dermal contact applications. The process nullifies cytotoxins normally present in objects formed by solid freeform fabrication techniques rendering such techniques as viable for the production of biocompatible devices such as stents, artery valve components, bone implant supports, pacemaker shells, surgical tools, and the like. In one embodiment, a custom hearing aid shell is produced by stereolithography from an acrylate photopolymer resin that was detoxified for long-term dermal contact application. The detoxification process makes three-dimensional objects created by solid freeform fabrication techniques available for products requiring biocompatibility.

Abstract: A manufacturing method of adhesive tape, by preparing a raw material of a biaxially or non-drawn, film or sheet on the back surface of which a release agent has been applied and to the which an adhesive agent has been applied, and subjecting the raw material to uniaxial drawing under heated conditions without deteriorating releasing and adhesive performance of the raw material, thus producing an adhesive tape having high-strength and low-elongation. The obtained adhesive tape has long and narrow bubbles elongated in the uniaxial drawing direction thereon.

Abstract: A transverse leaf spring structure and a manufacturing method for a composite transverse leaf spring is disclosed. The leaf spring is formed using a pre-formed tubular fiberglass fabric comprising longitudinally aligned and braided fiberglass fibers. The fabric is installed over an interior form, such as one or more inflatable bladders, and positioned within a forming mold. After resin is applied and cured to an appropriate stiffness within the mold, the mold is removed. The interior form is then removed from the composite leaf spring.

Abstract: The present invention is directed to a method for manufacturing a curved hose. The method is comprised of the steps of forming a hose pre-assembly, partially curing the hose on a linear mandrel, and then completing the curing of the hose pre-assembly on a curved mandrel.

Abstract: Compositions comprising a fluoropolymer having interpolymerized units derived from a nitrogen-containing cure site monomer and a catalyst composition are provided.

Abstract: A method of manufacturing a two-component skin by a “double slush” molding process is disclosed. In accordance with one aspect of the “double slush” molding process, after a first generally uniform layer of a moldable material that is at least partially cured is formed on a contoured surface of a mold, an additional amount of a moldable material is injected onto the at least partially cured first layer. Then, the mold is shaken to cause the additional moldable material to be generally evenly distributed on the first layer and form a second layer on top of the first layer. The mold also is heated to cure both the first and second layers and bond them together to form a two-component skin, shell, or body.

Abstract: A polymeric material including a microporous matrix disposed in a multi-block polymer having a backbone of the general formula: [(A)n−(B)m−(X)l]p wherein: A is a first copolymerized monomer; B is a second copolymerized monomer; X is a third copolymerized monomer the same as or different from A; n and m are the same or different and are each an integer in the range of from 30 to 3000; is 0 or an integer in the range of from 30 to 3000; p is an integer in the range of from 1 to 100; wherein the microporous matrix is defined by reactive cleavage of at least a portion of a pendant moiety on B. The polymeric material is produced by a process which comprises cleavage of at least a portion of pendant moiety on B while leaving the backbone of the copolymer intact. This approach facilities production of a substantially uniform distribution of very small pores of substantially uniform dimension.

Abstract: A method and a system for fabricating articles made from thermoset resins using an ionic mold release agent. The invention uses a mold having a metal oxide surface with enhanced mold release characteristics. The release agent is applied internally in the resin composition or externally on the metal oxide surface. The method includes providing a mold, forming a metal oxide surface on the mold, providing an ionic release agent, providing the acid or base conjugate of the release agent at the metal oxide surface, providing a thermoset resin in the mold, and curing the resin in the mold. A method of using float glass having a SnO2 enriched surface, wherein the method includes the steps of providing an ionic release agent externally to the tin oxide surface, is also disclosed.

Abstract: A method and apparatus for producing a composite component having a variable thickness includes placing a caul member over a plurality of laid-up prepreg plies supported by a mold and curing the lay-up in an autoclave. The mold includes a cavity for receiving the lay-up that is defined by a bottom surface, a plurality of walls extending upwardly from the bottom surface, and an open upper face surrounded by a mold edge. A support flange extends inwardly toward the center of the cavity from each of the walls at a predetermined distance upward from the bottom surface. The predetermined distance varies along the length of the mold and generally conforms to the outer profile of the composite component to be fabricated. The caul is positioned over the lay-up and defines a longitudinal axis extending along the length of the caul and a lateral axis extending along the width of the caul.

Abstract: The effects of processing parameters and suspension chemorheology on the deposition behavior of SFF components derived from polymeric-based gelcasting suspensions combines the advantages associated with SFF fabrication, including the ability to spatially tailor composition and structure as well as reduced tooling costs, with the improved handling strength afforded by the use of gel based formulations. As-cast free-formed Al2O3 components exhibited uniform particle packing and had minimal macro-defects (e.g., slumping or stair casing) and no discernable micro-defects (e.g., bubbles or cracking).

Abstract: A method of forming a cannula by forming a cannula mandrel assembly having a nare mandrel, a main body mandrel and mouthpiece mandrel; heating the cannula mandrel assembly, applying a polymeric material to the cannula mandrel assembly to provide a desired material thickness on the mandrel assembly to form the cannula, curing the polymeric material of the formed cannula and extracting the mandrel assembly from the cannula by disassembly and removal of the mandrel assembly parts.

Abstract: A method of forming a cannula by forming a cannula mandrel assembly having a nare mandrel, a main body mandrel and mouthpiece mandrel; heating the cannula mandrel assembly, applying a polymeric material to the cannula mandrel assembly to provide a desired material thickness on the mandrel assembly to form the cannula, curing the polymeric material of the formed cannula and extracting the mandrel assembly from the cannula by disassembly and removal of the mandrel assembly parts.

Abstract: A method of producing a hose-connector assembly, including the steps of forming by extrusion an inner resin tube layer, forming by extrusion an outer rubber protector tube layer having substantially the same length as the inner resin tube layer, so as to cover the outer surface of the inner resin tube layer over the entire length of the inner resin tube layer, to obtain a laminar tubular blank consisting of the inner resin tube layer and the outer rubber protector tube layer, cutting the laminar tubular blank into pieces, and press-fitting an end portion of a tubular connector in each of at least one of the opposite end portions of the inner resin tube.

Abstract: Small particles of polymeric material are produced by expansion of a mixture of monomers and a propellant. The size and shape of the particles can be precisely tailored by materials selection and expansion conditions. Particles of 10 nanometers to 100 microns can be produced. If monomers exhibiting solid state reactivity are utilized, the particles thus formed can be polymerized at any time after formation. The particles produced by this method can be molecularly imprinted by incorporating a template into the particle prior to fully curing the particle, in a manner which allows selective extraction of the template from the cured particle after formation without deformation of the imprint site. A two step polymerization process allows the particles to be deposited on and adhered to a wide variety of substrates without additional agents.

Abstract: The present invention is directed to a method for manufacturing a curved hose. The method is comprised of the steps of forming a hose pre-assembly, partially curing the hose on a linear mandrel, and then completing the curing of the hose pre-assembly on a curved mandrel.

Abstract: A compostion having improved fuel vapor barrier properties comprising a blend of about 20 to 80 weight percent of a first fluorointerpolymer with about 80 to 20 weight percent of a second fluorointerpolymer, the first fluorointerpolymer comprising a copolymer, terpolymer or mixture thereof formed by the copolymerization of two or more monomers selected from the group consisting of hexafluoropropylene, vinylidene fluoride and tetrafluoroethylene, and the second fluorointerpolymer comprising a copolymer, terpolymer or mixture thereof formed by the copolymerization of two or more monomers selected from the group consisting of hexafluoropropylene, vinylidene fluoride and tetrafluorotheylene, wherein the first fluorointerpolymer exhibits elastomer characteristics and the second fluorointerpolymer exhibits thermoplstic characteristics.

Abstract: The allergens and extractable protein content of a latex device can be reduced by subjecting the un-cured latex device to a pre-cure leaching treatment with a solution containing a protease, followed by curing and a post-cure leaching treatment.

Abstract: A rubber hose having a multilayer wall is formed of an inner layer of NBR type rubber having a high AN content, available at a low cost and highly impermeable to fuel and an outer layer of a rubber composition having a minimum Mooney viscosity of 25 to 65 at its curing temperature and highly resistant to flattening. Those layers are extruded and cured together without the aid of any mandrel owing to the inside diameter and wall thickness of the hose and the thickness of the outer layer which fall within specific ranges. This process enables the manufacture of a fuel hose having a high fuel impermeability at a low cost, while protecting its inner wall effectively from flattening during curing.