Abstract: A relatively rigid, air permeable panel suitable, for example, as a diffuser on a hard box vacuum cleaner housing. The panel is a composite of fabric and a polymeric frame molded in situ on the fabric. The disclosed molded frame technique avoids the necessity of separate fastening means between the fabric and frame and obviates the need for edge finishing of the fabric.

Abstract: A swab, such as for removing wax from the auditory meatus of an ear, includes a wad of absorbent material, such as cotton, arranged on an end of a stem and wherein the wad has a non-circular external configuration in a cross-section taken through a plane transverse to the axis of the stem. The wad may have at least one channel formed in the outer surface in which the material to be removed, i.e., the wax, becomes situated during the removal operation. The invention is particularly applicable to swabs which are intended for use by children or persons having delicate auditory meatus'. The stem of the swab is formed of deformable material and in manufacture the wad-stem assembly portion of the swab is subjected to a deformation pressure until the desired non-circular configuration of the wad is obtained. The wad supporting end of the stem is deformed at the same time to provide a non-circular configuration which substantially corresponds to the external cross-sectional configuration of the wad.

Abstract: A fibre reinforced plastics structure comprising a porous matrix of thermoplastics material and reinforcing fibres, the pores of said matrix being wholly or partly invested with a thermosetting plastics material.

Abstract: A method for manufacturing a predetermined shape of molded plastics, comprising the steps of introducing a foamable shell forming material in molding dies, introducing a hard core forming material having a foaming agent on the shell forming material, clamping the molding dies together, and heating both the material located in the molding dies by an induction heating.

Abstract: A method for manufacturing a decorative molding having an outer surface layer with a round peripheral edge, comprising preparing a desired shape of decorative base plate which has an outer decorative layer and a mounting surface of a plastic layer which shrinks when heated, pouring thermo-setting liquid plastic onto the outer surface of the decorative layer of the base plate to coat the outer surface with liquid plastic, and then heating the liquid plastic to cure the same and heating the plastic layer of the base plate so that a predetermined amount of shrinkage of the plastic layer takes place.

Abstract: Method and apparatus for molding an elastomeric component of a shaft seal while bonding it to a fluorocarbon seal lip member. The lip member is initially shaped as a flat washer, and a radially outer portion is flexed during molding to a frustoconical shape. Positive retention of the fluorocarbon washer during molding is assured. Radially inner portion of the fluorocarbon washer rests on a planar annular mold ledge, its radially outer portion overhanging a frustoconical mold surface. A ring of uncured elastomer is located above that radially outer portion and radially inwardly from the outer periphery of the ledge. The radially inner portion has a horizontal toothed mold portion with a series of concentric sharp tooth edges. This directly engages the upper surface of the washer and clamps it firmly and immovably against the ledge. When the mold is closed, the elastomer flows and forces the outer portion of the washer down on frustoconical mold surface while bonding elastomer to washer.

Abstract: A molding process for manufacturing laminated stoppers having an elastomer core and thin thermoplastic liner where a sheet of thermoplastic liner material having an elongation of at least 450% and the vulcanizable elastomer core material are placed in a mold and molded at a temperature above the vulcanization temperature of the elastomer core but below the crystalline molding point of the thermoplastic liner.

Abstract: A novel closure-making process and apparatus are disclosed for formation of plastic closures. The closures include a plastic closure cap which is compression molded to provide a closure having the requisite strength. The process includes steps for formation of a sealing liner within the closure cap if desired, with formation of a novel liner-retaining arrangement provided for secure retention of the liner within the cap. The process also includes steps for formation of a tamper-indicating pilfer band integrally with the plastic cap of the closure for formation of closures requiring a suitable tamper-indicating device.

Abstract: A synthetic-resin-made container having ornamentation is formed by forming a flexible and ornamented tubular member and inserting it into an outer sleeve, disposing the sleeve in a molding die to define an annular space inside the tubular member, and injecting molten resin into the space and then solidifying the resin to form an inner sleeve which is fused with the outer sleeve at both ends thereof, thereby hermetically sealing the tubular member therebetween.

Abstract: This invention reveals a method of manufacturing a rubber shoe sole having a decorative metal piece incorporated therein comprising molding a metal slug to comply to the shape of a fenced area in a shoe mold while simultaneously shaping and vulcanizing a rubber slug in the shape of said shoe mold at a temperature sufficient to vulcanize said rubber slug with the provision that said temperature be from about 0.degree. C. to about 80.degree. C. less than the melting point of said metal slug.

Abstract: A method of producing similar deep-drawn parts for double-walled structural parts having uniformly spaced walls and edge welding. During every deep-drawing procedure, a respective planar outer plate, which is placed upon the lower part of the tool, as is a filler plate, as well as a preformed or preshaped inner plate, which is placed over the tool punch, are shaped in common, whereby the preformed inner plate and the outer plate receive their final form or shape, and the filler plate is deformed into a preshaped inner plate for a subsequent deep-drawing procedure. The tool for carrying out this method is characterized in that the smallest spacing between the tool punch and the lower part of the tool corresponds to the entire thickness of the two inner plates and one outer plate.

Abstract: A method of forming a plurality of composite paperboard and plastic packages from a single blank of foldable paperboard. Each of the packages includes paperboard panels having at one end thereof an integral pocket for holding a packaged article. The pockets consist of shells which are formed integrally with the panels and have injected plastic therein covering the shells to form plastic liners.

Abstract: A method of manufacturing a raised relief, illuminated globe includes printing a hemispherical map design on a flat vinyl plastic sheet, forming the vinyl plastic sheet into a substantially hemispherical shape, positioning the hemispherically formed sheet in a mold cavity, positioning a mold core on the back side of the sheet, injection molding a styrene backing for the hemispherical shaped sheet to conform the sheet with the mold cavity including relief areas defined in the cavity wall, and removing the molded hemisphere from the mold. A second molded hemisphere is produced in substantially the same manner and is attached to the first hemisphere to form a complete globe. The printed map design of the globe is positioned in the mold cavity to insure that the relief areas are properly positioned with respect to the design.

Abstract: A method for molding an annular lip type shaft seal 10 of the type having an annular elastomeric shaft seal element 12 and a resin liner 14 (preferably polytetrafluoroethylene) integrally molded therewith and bonded thereto, including providing a step or shoulder 36 on the mold core 26 to prevent the resin liner 14 from flowing axially beyond a predetermined location during molding. The method includes providing a certain range of acute angles ".alpha." between the shoulder surface 42 and the liner forming surface 38 of the mold core surface 34, and a certain range of shoulder heights "d" relative to the liner thickness "t", for various values of the initial viscosity of the elastomeric preform 18. The percentage of rejects due to undesired flow of the resin liner 14 during molding has been greatly reduced.

Abstract: Molded product and method for providing a desired surface-hardness for its surface by means of a simple molding technique through several steps comprising the cutting of a thermoplastic film or sheet to the same form as the exterior form of the product, the placing of the cut piece on a mold-cavity surface, and the injecting of a molten resin for formation of the product into the mold cavity under a high pressure. The thermoplastic film or sheet is subjected, in advance, to a hard-coating treatment on its surface and a curing treatment to cure the agent thereon thereby forming a hard-coating layer on the surface of the product.

Abstract: A piston rubber with a body of substantially cylindrical exterior shape with one end thereof reinforced with a textile fabric wound into a roll that is arranged generally coaxial with the cylindrical body. The method for making the piston rubber involves winding a length of rubberized fabric around a mandrel and forming a sleeve of desired radial thickness, cutting the sleeve into bands of desired widths, and placing the bands and elastomeric material in a mold and curing the same to define a piston rubber.

Abstract: A method for making a molded high voltage splice body by positioning a conductive elastomeric electrode on a mandrel, positioning an extruded conductive elastomeric sleeve over the elastomeric electrode, sealing the ends of the elastomeric sleeve, placing the mandrel with the electrode and sleeve on it into a mold, injecting a curable insulating compound between the electrode and the sleeve under pressure and curing the insulating compound.

Abstract: A novel method of automatically decorating articles as they are formed, in-mold, of heated plastics flowing within and filling mold cavities. Pursuant to the invention an elongated tape or strip of decorating material is automatically advanced and pre-fed and positioned in the molds at each molding cycle, interfacing therein automatically with the plastics as they fill the molds under heat and pressure; as the article is thus formed, the decorating material forms therewith a unitary, permanent decorating part thereof.

Abstract: A novel composite pulley construction is provided, which comprises a continuous, metal peripheral belt supporting and bearing surface, and a plastic body. Also provided is a novel method for making a composite pulley.

Abstract: The process of forming a laminate by molding, preferably either by compression or injection molding, a polymer which is incompatible with PVF.sub.2 onto the surface of a preformed laminate sheet of a PVF.sub.2 and a polyalkyl methacrylate, with the preformed laminate have been previously obtained by the coextrusion of the PVF.sub.2 and polyalkyl methacrylate.

Abstract: A process for making a composite closure having a plastic cap with specially configured pedestals that are interconnected to a plastic liner. In one embodiment, the pedestals are each formed with an overhang, such as a mushroom-shaped overhang, to provide a mechanical interlock with the liner. In other embodiments, the pedestals are each formed with a fusible heat concentration zone that is fused to the liner as the liner is compression molded and heated in the cap. In one embodiment, each of the fusible pedestals are formed with a cylindrical configuration. In another embodiment, each of the fusible pedestals are formed in the shape of a pyramid.

Abstract: A method and device for manufacturing a record carrier is disclosed in which a liquid moulding resin is deposited in a cavity formed in the surface of a mould which also has at least one data track. Thereafter a flexible substrate, having a central projection, is deformed into a convex shape and is pressed against the moulding resin. As the projection on the substrate enters the mating cavity in the mold, the resin is squeezed out of the cavity and rolled out across the mould surface by the substrate which is flattened into a planar form during the pressing step. The moulding resin is then cured and the assembly of the substrate with attached, cured resin layer is removed from the mould.

Abstract: A method of processing the end and joint portion of a decorative molding comprising a synthetic resin base having laminated thereon a layer of metal foil is disclosed. In accordance with the invention areas of reduced thickness are formed in the moldings to be joined such that a substantially level joint can be formed without using a separate joining member.

Abstract: Insulative sheath for high voltage cable splices has inner semiconductive member with inwardly directed bosses for positioning the sheath radially of the cable and splice and for contacting the connector of the splice to suppress corona discharge.

Abstract: A method of making a wall of a container which wall is to be ruptured to gain access to the interior of the container, the method comprising forming a weakening in the wall corresponding to the path along which the wall is to be ruptured, locating the wall between mould tools which are formed as to one of them with a bead recess which will overlie the weakening and as to the other with a rupture recess in register with the bead recess, injecting material into the bead recess to displace the wall regions adjacent the path into the rupture recess to further weaken the connection between the wall parts to either side of the said path, and to form a seal therebetween and removing the wall from the tools.

Abstract: A helical fusible element is supported by an element support member which is disposed between two terminal assemblies, which terminal assemblies are of larger diameter than the diameter of the combination of the fusible element and the element support member. A flexible container is formed around the element support member and the fusible element on the circumference of the terminal assemblies to enclose these elements except for the ends of the terminal assemblies. A hole through the enclosure is provided through which a suitable particulate arc quenching material is admitted so as to completely fill the enclosed region. The hole is then sealed. The completed subassembly is then encapsulated in a resinous compound using a split mold. The contraction of the resinous compound as it cures compresses the flexible container and the particulate arc quenching material, thereby insuring maximum density of the arc quenching material without interfering with the desirable porous nature of the arc quenching material.

Abstract: A method of manufacturing reinforced plastic hoses comprising extruding and shaping plastic material into a plastic tube which is provided around its outer surface with a serrated portion, heating said plastic tube so as to soften said serrated portion, and covering the outer surface of said plastic tube with a reinforcing layer.

Abstract: In a method of injection-moulding articles of plastics material onto a preformed web inserted into the mould, the web is held under substantially constant tension during the closing of the mould, between a pair of clamps, the proximal clamp being fixed relative to the mould and the distal clamp free but bearing a load to furnish the desired tension in the web. The load may be imposed by a weight attached to the distal clamp, conveniently by means of an electromagnet.

Abstract: A method for supplying a prepreg having substantially no excess resin while at the same time having an aggressive tack. Small discrete amounts of additional resin are selectively applied to a surface of the prepreg sheets in a regular array. The resin is applied at a sufficient viscosity that it does not sink into the prepreg fabric. The additional resin typically covers less than 25% of the surface and constitutes between 0.1% and 3% of the prepreg weight. The additional resin may be applied by a gravure roller having a surface etched with an appropriate array of indentations. A doctor blade partially defines a reservoir of resin in contact with a portion of the gravure roller and wipes the surface, thereby leaving resin only in the indentations. The doctor blade may be oscillated parallel to the roller axis to prevent accumulations of short fibers from impairing the wiping action.

Abstract: A method for bonding a layer of porous polymeric material to a rigid implantable portion of a prosthetic device, which includes the steps of (a) forming a substrate by coating the implantable portion with material which is chemically compatible with the porous polymeric material and which has a melt viscosity and/or melting temperature lower than that of the porous polymeric material, (b) covering the substrate with a porous polymeric material in powder form capable of forming said porous polymeric layer for forming a composite coating on the implantable portion, and (c) heating the substrate and porous polymeric material to a temperature high enough to cause the substrate material to flow into the adjacent pores and low enough so that the porous material will maintain its shape so that the porous layer will be bonded to the substrate and the outer pores will be open to accommodate tissue ingrowth, and an apparatus formed by said method.

Abstract: A method for the preparation of composite products wherein a foam expands in contact with a laminated sheet, one of the layers of which is metallic, the pressure generated during expansion of a foam forces the laminated sheet to adopt a desired configuration and the foam adheres to the laminated sheet. Composite products having a mirror-like appearance may be prepared by the method.

Abstract: Thermoforming, utilized for making articles from sheets of thermoplastic ins, does not always yield articles having desired strength properties. It has been suggested that both thermoplastic and thermosetting layers be used to making the articles stronger. However it was virtually impossible to bond the layers together. A process is provided herein for obtaining that bond.

Abstract: The invention relates to a method of producing a molded plastic article simulating a base having one or more headed shanks extending therefrom by an injection molding operation using a specially shaped mold followed by deforming of the molded article by a heated platen.

Abstract: A method for making a shaft seal of the type including an elastomeric body and a polytetrafluoroethylene sealing element comprising inserting a metal shell (if employed in the seal), a synthetic rubber blank prep form and a polytetrafluoroethylene sealing element into a transfer or compression mold, and then closing the mold to simultaneously form a sealing lip portion of the polytetrafluoroethylene sealing element into the desired shape, mold the rubber into the desired shape and bond the rubber to the shell (if used) and to the anchor portion of the polytetrafluoroethylene sealing element.

Abstract: A method for making an annular shaft seal of the type having an elastomeric sealing element bonded to a metal shell having a guard or scraper portion having a sharp I.D. edge, in which the sharp I.D. edge is formed or "pierced" during the molding process simultaneously with the elastomeric sealing element being molded and bonded to the shell.

Abstract: A machine for making a composite article including a sheet material blank and an injection moulding thereon, comprises first and second cavity tools which are relatively movable between open and closed conditions and in the latter define a cavity, and a core tool movable relative to the cavity tools between open and closed conditions in the latter of which the core tool and first cavity tool together define a blank receiving cavity and the core and first and second cavity tools together define a mould cavity, the second cavity tool lying between the first cavity tool and the core tool when the tools are in open condition and supporting guide means for guiding a blank falling under gravity from a blank magazine to a position in the path of relative movement tools and between the core tool and the second cavity tool when the tools are in open condition, stop means on the core tool extending into the guide means to support a blank therein above the tools when the tools are in closed condition and to permit the b

Abstract: A self-supporting tubular filter including a sleeve of filter material and a frame formed by longitudinal and circumferential ribs attached to the sleeve. The filter is characterized by a longitudinal separation along a substantial length of the sleeve which is spliced together by one of the longitudinal ribs. That rib extends through the separation so that it overlies and is attached to the interior and exterior surfaces of the sleeve adjacent to the separation. Also disclosed are the use of the filter as a microemboli blood filter and a method of its manufacture employing a single male core pin with first and second female molds.

Abstract: Preprinted rectangular blanks of longitudinally stretch-oriented foam sheet material are formed into cylinders by a continuous folder and seamer and transferred onto mandrels on which they are shrunken by heat to assume the shape of the mandrel. In forming containers, means are provided to place bottom blanks on the mandrels prior to the loading of the cylinders thereon so as to shrink the cylinders to sidewall shapes overlying the bottom blanks. The top curl on containers such as drinking cups and food tubs is formed after shrink forming and the bottom seam of the container is also reinforced by ironing after shrink forming. A method of continuously forcing and filling containers on a continuous in-line basis is also provided.

Abstract: A method and an arrangement for lining articles are disclosed which are particularly well-suited for use in the lining of melting ovens. The arrangement includes a mold member which has a surface with the configuration corresponding to the face of the inner wall of the oven chamber and comprises a plurality of circumferentially adjacent sections detachably connected to one another. A plurality of circumferentially adjacent flexible plate-like elements of a refractory material are arranged at the surface of the mold member and connected to one another to thereby form a circumferentially complete refractory member. The plate-like elements are connected to one another by refractory adhesive substance. They have adjacent end portions overlapping one another, which portions are connected to one another by the above refractory adhesive substance, and are fixed to one another by adhesive strips.

Abstract: A foam-padded article such as an auto seat cushion having an outer upholstery integrally adhered to the foam is made by vacuum forming an airtight upholstery layer to which the foam adheres and then introducing the foamable cushioning material and foaming it into contact with the formed upholstery. Controllable folds are intentionally formed in desireable locations in the article, as for example, in one or more corners of a cushion not subject to heavy wear, by pressing one or more fold-forming plates into the upholstery layer in the forming mold before the foamed cushioning material sets thereby tensioning the remainder of the layer. The apparatus yieldably clamps the edges of upholstery surrounding the area to be folded while non-yieldably clamping it in areas to be tensioned. The folds so formed may be sealed with an adhesive before foaming occurs thereby assuring more permanent tensioning of the upholstery in the product.

Abstract: In a fuser roll for electrostatic copying machines comprising a cylindrical metal core surrounded by a cylindrical body of elastomeric material having an outside cylindrical sleeve of protective material, the end surfaces of the elastomeric material are protected from the deleterious effects of silicone fluid by sealing rings of elastomeric material such as fluorosilicone which is resistant thereto. The rings, which are rectangular in cross section and are made of uncured, deformable material, are inserted in the ends of the sleeve with the ends of the sleeve protruding. The sleeve is assembled with the metal core and placed in a cylindrical mold. Silicone rubber is injected into the space between the core and the sleeve and the sleeve and rings are expanded into contact with the mold wall. The roll is then cured.

Abstract: Method of molding granular polytetrafluoroethylene powder which comprises compressing the powder in a mold at a pressure of between about 10 and 50 bars to form a preform and subjecting the preform to isostatic molding at a pressure of between about 100 and 1000 bars.

Abstract: A compliant roller for use in a xerographic fusing apparatus is made by placing a rigid gudgeoned roller core in a mold assembly with a preshrunk outer sleeve positioned about the interior surface of the mold and by forcing an elastomeric siloxane, e.g., silicone rubber, between the core and the sleeve. The sleeve is comprised of a material which contains tetrafluoroethylene and/or hexafluoropropylene copolymers. The ends of the roller are sealed with an epoxy resin and a forming fixture to form an oil tight and airtight seal.

Abstract: A method of permanently marking a rubber product is provided wherein the rubber product has a debossed marking of a particular color in a portion thereof and a layer of rubber is defined as an integral part of the rubber product and surrounds the marking with such layer of rubber having a color which is different than and contrasts the particular color.

Abstract: A method of making a container, particularly a rectangular tray-like container, in which a blank is provided having side panels which are displaced to form the side walls of the container. The blank is clamped in its container - forming shape between mould tools with adjacent ends of the side panels juxtaposed end corner seams and a lip are injection moulded to seam the side panels and form a peripheral lip on the free edges of the side panels remote from the base panel. The mould tools shape the free edges of the side panels to an internally concave form between the juxtaposed side panel ends before moulding so that shrinkage of the moulding will accentuate the concavity to give a predetermined consistent shape to containers so produced and avoid unpredictable buckling and deformity.

Abstract: A method of incorporating a pre-cut foil sheet in a container moulded from a thermoplastic material by injection moulding techniques during the process of moulding the container. The foil sheets are fed singly from a store to a position of registry with the free end of the plunger forming part of the mould of the injection moulding apparatus, whereafter the mould is closed, the foil sheet being wrapped around the plunger upon entry thereof into the die. A moulding compound is then injected into the mould. The stream of moulding compound entering the mould is guided so that the foil sheet is either located on the inner surface of the moulded object or on the outer surface thereof.

Abstract: A process for the production of lettering or symbol templates by production of symbol cut-outs in a template sheet consisting of thermoplastic plastic, characterized by forcing the cut-out portions of the symbols in a shaping or forging step, and subsequently cutting off the protruding forced-out portions.

Abstract: Method of making a precision injection-molded form for an inductance coil comprises a cylindrical core member having a surface of relatively low dimensional precision, and a thin plastic layer molded over the surface to provide a surface of high dimensional precision for supporting the windings of the coil. Metal insert-members having threaded axial bores and radially extending wing portions are provided at either end of the core to establish electrical contact with the winding and a mounting capability for the assembly. The coil form is formed by injection molding techniques and apparatus which provide for axial compression of the assembly prior to molding to obtain a predetermined longitudinal dimension, and for equalization of forces exerted during molding to prevent longitudinal deformation.

Abstract: A method of forming a three-dimensional colored design, such as a simulated animal bone, in production material which is to be formed into an article such as a handbag, including forming a master, forming a mold member, and applying a colored design to the production material. A light-transmitting film, which includes a colored design formed on one surface thereof, is positioned intermediate the production material and the mold member with the colored design facing the production material. The production material, the light-transmitting film, and the mold member are heated and pressed together in a high frequency heating press, and the production material and light-transmitting film are hardened, so as to form the three-dimensional colored design in an efficient, convenient and economical manner.

Abstract: Method for loading and unloading of isostatic presses of the type wherein pre-formed, or equivalent, shapes of powdered metal, ceramics, clay and the like are compressed under very high pressures to form compacts suitable for use as such or for subsequent operations, such as forging, machining, firing or the like as may be appropriate for the particular powdered material. Method is disclosed in connection with the use of an isostatic press having a container including a cylindrical sleeve of elastomeric material for receiving the objects to be compressed under pressure of hydraulic fluid applied to exterior of the container. Bodies of rigid or elastomeric material which also may serve as plugs for the ends of the sleeve are movable from inside to outside the press to positions to receive a pre-form.