Abstract: A method for molding high temperature composites that transmits more uniform pressures to the surface of the composites. A compliant glass, glass-ceramic, or ceramic layer is caused to apply pressure to a composite precursor and heat is applied to the composite precursor to form a composite.

Abstract: A method of making a high strength carbon-carbon utilizing a solid flowable particulate polymer as a pressurizing medium. A resin impregnated carbon fiber reinforced prepreg is disposed in a pressure vessel and the vessel is substantially filled with a solid flowable particulate polymer. The prepreg is exposed to sufficient temperatures and pressures to cure the prepreg to form a carbon-carbon precursor which is subsequently exposed to temperature and pressures sufficient to post-cure the carbon-carbon precursor. The post-cured carbon-carbon precursor is exposed to temperatures and pressures sufficient to carbonize said post-cured carbon-carbon precursor to form a carbon-carbon composite.

Abstract: A method for forming a part inserted in the auditory canal of a hearing impaired person, said part being either an otoplastic or a carrier part of the hearing aid insertable into the auditory canal or an ear adaptor member for a hearing aid to be worn behind-the-ear, characterized by providing an expandable elastic member, coating said elastic member with a hardenable material, inserting the coated member into an ear of the person who is hearing impaired, allowing the hardenable material to harden to retain the outside contour of the part. The elastic expandable member may be either a porous member which is partially saturated on the outer surfaces or may be a smooth member which is coated with the hardenable material. If desired, a physiologically compatible coating may be applied onto the hardened surface layer subsequent to the hardening process.

Abstract: A method for preventing hardening of plastic material in a dispenser tip during periods of nonuse of the dispenser tip. The method involves providing a balloon around the dispenser tip, and then filling the balloon with plastic material.

Abstract: Apparatus and methods for compressing a mass utilizing a plurality of interfitting anvils mounted for movement relative to one another along co-planar paths and include faces which, when the anvils are operatively moved relative to one another, exert compression on a mass positioned between the faces in at least two directions in a plane simultaneously. The faces of the apparatus can be so shaped that the cross section of the mass being compressed is urged toward a shape other than that of a regular polygon. Methods of the invention include the consolidation of a mass of compactable material enclosed within a hollow tube having deformable walls, the extraction of juice or oil from fruit or seeds and the internal fracturing of solids so as to swell materials such as solid rocket propellants.

Abstract: Thermoplastic compositions comprising polyphenylene ether resin and polyamide resin are disclosed. The compositions further include a compatibilizer component, and an additive combination which includes both a metal stearate and an amide compound.

Abstract: This invention is directed to a thermal barrier layer particularly adapted for insulating a solid flowable particulate polymeric pressure transfer medium from elevated temperatures during high temperature molding. A method useful with the thermal barrier comprises transferring pressure from a pressure means via the thermal insulation layer to an article and exposing the article to temperatures of about 316.degree. C. to about 1371.degree. C. An exemplary thermal barrier comprises at least two flexible layers of beads having a thermal insulation of less than about 2 k.

Abstract: A method of moulding racquets to define stringing holes in the moulded frame. The method includes forming at least one approximately ladder-shaped member having two side pieces interconnected by rung pieces, with the side pieces substantially conforming to the curved shape of at least part of the frame of the racquet; entrapping the ladder-shaped member between two mould plates defining a mould cavity; injecting a plastic material into the mould cavity to mould the frame around the rung pieces; and forming the ladder-shaped member in two parts and separating the two parts after the frame has been moulded to remove the ladder-shaped member from the moulded frame.

Abstract: A method of making a foam filled polymer article includes the steps of compressing an expandable foam material (12) and containing the compressed expandable material (12) in a degradable container, such as a polyethylene bag (16). An outer polymer shell (10) is formed while degrading the container (16) therewithin, such as by rotation molding. The shell (10) is filled with the uncontained expandable foam material (12).

Abstract: A system is provided for generating prescription wheelchair seats or specialized seating or body supports. The system includes a deformable seat portion which is formed to specialized dimensions of a seated patient. A planar, linear, array of linear transducers is stepped across the form in one dimension forming a series of signals representative of generally planar cross sections of the form. This series of cross-sectional signals is provided as an input to a numerically controlled cutting device which cuts a series of sheet stock foam in accordance with each cross-sectional area measured. These cross-sectional pieces are then assembled into the prescription seat.

Abstract: Method for producing an ice scupture employing the steps of forming rigid metallic mold halves from the objects, said mold halves having recesses which collectively define the object; yieldably joining said rigid mold halves together at discrete locations; filling said mold halves with a freezable liquid; chilling the assembly sufficient to freeze the freezable liquid; allowing the mold halves to become differentially displaced from one another as the freezable liquid expands; disassembling said mold halves from one another to remove the ice sculpture therefrom peeling away said rubber mold from sculpture. In another embodiment, the rubber mold is eliminated and replaced by a sealing gasket. Additives may be employed to add color and/or obtain clarity.

Abstract: A process is disclosed for obtaining wax honeycombs using a rigid walled mold made from walls of an elastic material which dilates under heat and contracts when cooled, the mold having at least one wall with a multiplicity of internal, parallelepiped, elastic finger shapes projections of hexagonal section extending partially through the mold. Molten wax is poured into the mold with dilation of the elastic material, and the wax is allowed to cool and solidify with contraction of the elastic material. Finally, the walls are removed from the solidified wax which is in the form of a honeycomb having a multiplicity of hexagonal cells corresponding to the projections, in at least one face.

Abstract: An apparatus is disclosed for the reduction of mold cycle time. A heat recoverable member in a compressed state is placed within a channel defined relative to the surface of a mold. A hardenable liquid used to form the article then flows in an accelerated manner through the channel. Thermal energy supplied to the heat recoverable material thereafter causes the heat recoverable material to expand within the channel, thereby displacing the hardenable liquid from the channel. The temperature of gelation of the hardenable liquid and the recovery temperature of the heat recoverable material may be selected such that the channels are substantially filled by the heat recoverable material prior to the hardening of the hardenable liquid. In this manner, the heat recoverable material becomes flush with the surface of the mold prior to hardening of the liquid so as to yield an article of manufacture having a relatively planar surface.

Abstract: A strip of fiber-reinforced plastic composite is wrapped around a neck and peghead insert positioned right-side up in a neck mold. A pressure plate having a fingerboard secured thereto is then lowered onto the mold and pressure applied to integrally mold the instrument neck with the fingerboard bonded thereto.

Abstract: A process for producing reinforced laminate plastic panel structures by thermoplastic compression employing internal mold mandrels which are significantly embrittled during or subsequent to the compression step. Hat stiffened panels formed from two thermoplastic resin sheets may be produced by using elongated mandrels formed of ceramic particulate material adhered together by a binder such as an alkali metal silicate. The mandrels are arranged between a skin sheet and hat stiffener sheets with the respective sheets disposed between the platens of a hydraulic press or other suitable compression molding mechanism. Sandwich laminate structures can be formed employing free thermoplastic resin sheets with a first set of ceramic particulate mandrels interposed between one adjacent pair of sheets and a second set of such mandrels interposed between the other adjacent pair of sheets.

Abstract: An article is molded by contacting it with a solid polymer medium, such as an especially low strength unfilled silicone rubber which is solid and able to flow readily. Thermal expansion of the medium or mechanical force is used to create molding pressure and thereby provides a substantially uniform pressure on the article precursor. Various temperature and pressure cycles can be attained; constant high pressures can be maintained on the article precursor during cooldown, optionally aided by flowing of medium to and from a vessel in which the article precursor is being molded. The method is particularly adapted to molding filler or fiber reinforced thermosetting polymer composite articles.

Abstract: Powder is filled in an axially elongate powder filling space defiined in a flexible pressure tube, and the pressure-bearing surface of the flexible pressure tube is pressurized with a pressurizing fluid, from a wall portion of the pressure tube which corresponds to a localized region of the powder filling space progressively toward another wall portion of the pressure tube which corresponds to an end of the powder filling space, until the pressure-bearing surface of the pressure tube is pressurized in its entirety, thereby compacting the powder in the powder filling space. Therefore, air in the powder is progressively squeezed toward the end of the powder filling space where the air can be discharged. Thus, no air remains trapped in the powder, and a formed product is prevented from being damaged, which enables elongate products to be produced.

Abstract: A process for producing a green composite structure by isostatic compression and filtration. A suspension of colloidal size matrix powders is established in a carrier liquid. The suspension is incorporated into a die chamber having a filter opening containing a filter which is permeable to filtrate from the suspension under applied pressure but substantially impermeable to the matrix powders. An elevated pressure is isostatically imposed on the colloidal suspension within the die chamber. The pressure is maintained for a period of time to expel at least 20% of the liquid originally in the colloidal suspension through the filter opening. A specific die chamber comprises a rigid cage structure and an expandable bladder within the cage structure into which the colloidal suspension is introduced. The cage structure is disposed within a pressure vessel which can be initially evacuated to cause the bladder to conform to the cage structure and then pressurized with fluid for the isostatic compression procedure.

Abstract: A light reflection material comprises transparent body of organic glass having therein a thin through hole or holes whose inner wall is smooth. This material is useful for an ornamental material, a lighting material, eye-obstructing material, shading material, etc.This material is manufactured by pouring a raw material into a mold within which a thread or threads of synthetic fiber are straightly or curvedly set according to aimed pattern and pulling the thread or threads out of the formed body to form a thin hole or holes or pulling the thread or threads to separate them from the inner wall of the hole or holes. As a result of it, a hole or holes of a shape and number corresponding to those of the thread or threads are formed in the formed body.

Abstract: The invention is concerned with the method of compression molding a metallic or ceramic powders. The method includes the step of maintaining a negative pressure within a first mold of noncompactable powders for intimately contacting on its inner surface a pouch-like member of thin-walled resilient material for producing a second mold, and the step of compactly charging starting powders into the second mold and exhausting air from and sealing the second mold, taking out a pre-molded body of the metallis or ceramic powders together with the second mold and the step of processing the pre-molded body by a cold or hot isostatic press.

Abstract: A collapsible core and molding apparatus and method for molding a plastic article having an undercut and a non-undercut portion. The collapsible core includes a center core pin and a core sleeve about the core pin and with the core pin having a small plurality of alternating, uniform, narrow, non-collapsing segments secured to the center pin and the same plurality of uniform, alternating, wider, arcuate, collapsing segments secured to the core sleeve, the wide collapsible segments adapted to move between the non-collapsed segments to form the expanded position for a molding operation where the wide segments are separated by the narrower segments, and a collapsed position where the collapsible segments collapse radially inward on the axial withdrawal of the center pin to form a generally cylindrical, cross section, arcuate area and to permit the ejection of a small molded plastic article from the mold.

Abstract: A method for continuously producing molded members. Prior to dispersing the material for the molded members onto the molding belt, the edge zones of the molding belt are covered by protective belts that move along with the molding belt. This prevents the edge zones of the molding belt from getting very dirty.

Abstract: Fabrication of contact lenses whereby the yield of lenses removed from plastic casting molds is significantly increased. In fabricating contact lenses where a lens is initially formed in a plastic casting mold, the mold is compressed to a degree sufficient to initiate permanent deformation of the mold material, in progressive steps, incrementally decreasing in diameter from a starting diameter substantially larger than the diameter of the molded lens, until the lens self-detaches from the mold.

Abstract: Consolidation of thermoplastic composite panels in a platen press is facilitated by the positioning of resilient pads between the platens and the composite to be consolidated.

Abstract: A method and apparatus for manufacturing ceramic parts which have a small bore relative to the outside diameter of the part.

Abstract: A trapped rubber molding method including a die positioned within a fixed-volume, rigid mold, the die being surrounded by an integral solid silicone rubber material which has been cured within the mold at an elevated temperature. The die and mold closure are thermally isolated from the remainder of the mold. The die and the silicone rubber material adjacent thereto are selectively heated and cooled. The opposite end of the mold is selectively heated and cooled. This configuration results in the ability to independently control temperature and pressure on the molded part during the molding process.

Abstract: A system for generating a prescription wheelchair or other seating or body support arrangement includes a deformable seat portion. A patient to be fitted with the wheelchair is placed upon the seat deforming a surface thereof. A signal representative of force distribution resultant from the patient along the seat is generated. In accordance with this signal, the seat surface may be selectively varied by a plurality of pneumatic actuators. An updated force distribution signal is generated. In this fashion, a means and method is provided for arriving at preselected force distribution of the patient on the wheelchair seat. This data is made available for transmission to a fabrication unit from which a permanent seat cushion with the desired characteristics may be fabricated.

Abstract: An elongate packing is sandwiched between two sheet-like mold members in an encircling manner to define a mold cavity therebetween, then a thermosetting plastic material is poured into the mold cavity, and the thermosetting plastic material is heated and set in the mold cavity. The upper and lower mold members are held against deformation transverse thereof so as not to be deformed by the shrinkage of the thermosetting plastic material when the latter is set, and the packing is allowed to move transversely thereof for following the shrinkage of the thermosetting plastic material when the latter is set. In some embodiments, the packing comprises a packing body adapted to be sandwiched between the mold members for preventing the plastic material from flowing out of the mold cavity with a flange joined to the packing body and adapted to be held against peripheral edges of the mold members.

Abstract: A process for manufacturing spherical objects which includes the steps of ejecting into a reaction medium layer a predetermined amount of liquid material which form spherical objects and allowing the spherical mass produced by the ejection to react and set while floating in the reaction medium layer. The reaction medium layer is restricted by a first blocking and protective liquid layer having a smaller specific gravity than the reaction medium layer and located above the level of ejection and a second blocking and protective layer having a greater specific gravity than that of the reaction medium and located below the level of ejection.

Abstract: Polymerized foam material in flat billet form is enclosed in a heat-retaining envelope and heated to forming temperature then promptly loaded into an innovative unheated forming press and accurately formed before cooling below forming temperature. The heat-retaining envelope has an expansive skin on one side and a contractive skin on the other side to facilitate bending without wrinkling or other distortion. The forming press utilizes a rigid male form punch and a spring-tensioned elastic belt, supported on a pair of variably-spaced rollers, initially presenting a flat compliant surface upon which the heated workpiece is placed. Pressure from the form punch progressively deflects the workpiece and the belt, which becomes a compliant mold member conforming itself and the workpiece progressively around the form punch to yield an article of required carved shape, free of wrinkles or tool creep distortions.

Abstract: A method for the reductin of mold cycle time. A heat recoverable member in a compressed state is placed within a channel defined relative to the surface of a mold. A hardenable liquid used to form the article then flows in an accelerated manner through the channel. Thermal energy supplied to the heat recoverable material causes the heat recoverable material to expand within the channel, thereby displacing the hardenable liquid from the channel. The temperature of gelation of the hardenable liquid and the recovery temperature of the heat recoverable material may be selected such that the channels are substantially filled by the heat recoverable material prior to the hardening of the hardenable liquid. In this manner, the heat recoverable material becomes flush with the surface of the mold prior to hardening of the liquid so as to yield an article of manufacture having a relatively planar surface.

Abstract: A method of molding a polymeric containing article by exposing the article to ultraviolet radiation and a substantially uniform pressure. The method includes placing the precursor article within a pressure vessel and substantially filling the vessel with a solid, flowable, polymer medium that is substantially ultraviolet transparent under pressure. The polymer medium is pressurized so as to produce a substantially, uniform predetermined pressure on the surface of the article and the article is exposed to ultraviolet radiation that passes through the polymer medium to cure the article. Alternatively, the polymeric article may be passed through the medium containing vessel during exposure to ultraviolet radiation and a substantially uniform pressure.

Abstract: A process for applying tension to the extending ends of a thin wire core of a mold to apply tension to the core during the molding process to maintain alignment of the core at all times during the molding process. Also included is apparatus for carrying out the process. Also included is a generally tubular part having a fine diameter hole therethrough.

Abstract: A method of forming a shaped article from a stock of preformed, thermoplastic, syntactic foam material of hollow microspheres in a thermoplastic polymer matrix, comprising heating the preformed syntactic foam to a temperature above the softening point of thermoplastic polymer matrix and applying differential pressure over at least one surface of the foam material through the medium of a plastically deformable diaphragm member to cause the foamed material to conform to a desired shape. Shaped articles of syntactic foam material, optionally having a surface coating of unfoamed, preferably fibre reinforced thermoplastics materials are provided in a more versatile and convenient manner than curing or sintering syntactic foam material in a mould.

Abstract: Apparatus for producing cast products which include a filling unit wherein elastic moulds of open-bag shape are filled with non-solid materials, a solidifying unit wherein the materials are allowed to solidify in the elastic moulds, and a withdrawal unit wherein the solidified materials are withdrawn from the inside of the elastic moulds in the filling unit, the elastic mould is positioned under a vacuum when filling starts. The apparatus provides cast products without mould joint marks, low mould production costs and prevention of mould breakage as well as a great degree of production simplification.

Abstract: This invention relates to a passive restraint for an automobile, and moe particularly, to a knee blocker for automotive applications that is positioned under the steering column forward of the knees. In order to provide energy absorption, the knee blocker includes an energy absorbing core filled with a plurality of thermoset resin pellets. The energy absorbing core is disposed between a metal stamping and a vinyl foam skin padding. Each of the pellets consist essentially of substantially uncured thermoset polymeric resins and microspheres which have been intermixed and extruded. Each of the pellets also has a coating of a B-staged resin. These thermoset pellets are made in the following manner. A low viscosity thermoset resin and microspheres are mixed together without melting the thermoset resin and extruding the mixture to form a continuous strand of paste-like uncured material.

Abstract: Carbonaceous powders are blended with a high coking value pitch, e.g. mesophase pitch, formed into shaped bodies and then simultaneously compressed and baked in an envelope of finely divided, non-reactive particles, followed by graphitizing, if required, to produce high strength, high density carbon or graphite articles.

Abstract: Herein disclosed is a method of making a porous mold by using an upper case which bears lines for forming channels for water and air communications.

Abstract: A flexible mold and method of forming a base defining either a full base or quadrant base of a dental model is provided with a perimeter member for defining the side walls of the base and a shelf extending inwardly from the rear side wall for delineating a slot at the rear of the base, which slot is usable for adhering an arm of an articulator. The configuration of the slot and/or the rear side wall of the base is striated for better adherence with the attached articulator.

Abstract: A method of molding oriented structural yarn/polymer matrix composite structural articles in which a preform of oriented yarn layers saturated with a resin is placed in a shape-defining mold, which is put in an enclosure, and subjected to heat and pressure to cure the resin, after which a cooling medium may be introduced. To enable the use of lightweight multi-part molds, and a mixture of pressure is distributed evenly, an internal liner is collapsed about the mold prior to curing. The process is extremely productive, and allows for accuracy and reproducibility through the use of real time temperature monitoring and closed loop feedback control.

Abstract: A method of moulding racquets to define stringing holes in the moulded frame. The method includes forming at least one approximately ladder-shaped member having two side pieces interconnected by rung pieces, with the side pieces substantially conforming to the curved shape of at least part of the frame of the racquet; entrapping the ladder-shaped member between two mould plates defining a mould cavity; injecting a plastic material into the mould cavity to mould the frame around the rung pieces; and forming the ladder-shaped member in two parts and separating the two parts after the frame has been moulded to remove the ladder-shaped member from the moulded frame.

Abstract: A method of recovering a solid flowable polymer medium that is capable of being used as a pressurizing medium for high temperature molding from contaminants. A polymer mixture containing contaminants that was a solid flowable polymer medium prior to exposure to temperatures in excess of about 316.degree. C. during its use as a pressurizing medium is disposed in a solution. The solution has a specific gravity greater than the solid flowable polymer medium. The solid flowable polymer medium is separated from the surface of the solution and contamination settles to the bottom.

Abstract: A window assembly includes a transparent glass sheet and gaskets formed by curing a polymeric gasket material in situ on the glass sheet to encapsulate a marginal peripheral edge portion thereof. A glass sheet to be utilized in a vehicle door has a front edge, rear edge and a lower edge to each of which is adhered such a gasket. In addition, a bracket means for attachment to a scissor linkage for raising and lowering the window can be secured to the lower edge of the window. The gaskets are formed in a mold with the transparent sheet and bracket means, typically by a reaction injection molding process. Each of the front and rear gaskets may have a flange portion thereon for insertion in an opening in a gasket attached to a frame of the window opening in the vehicle door.

Abstract: A method of making a porous mold used in pressure casting for forming ceramic articles, which includes the steps of: removably attaching a plurality of apertured holding members in an array at a desired interval to the inner face of an upper case made of a rigid material; threading a flexible line into the apertures of the holding members in each row to hold it at a predetermined spacing from the inner face of the upper case, at least one of the two ends of the flexible line being extended to the outside of the upper case; casting slurry into a mold cavity which is defined between the upper case and a lower basic case joined to the former case to form a porous mold; removing the upper case from the porous mold after the slurry has cured, while leaving the holding members together with the flexible lines in the porous mold; and extracting the flexible lines from the porous mold to form channels in the porous mold.

Abstract: The invention provides a method and apparatus for the high pressure injection of polyurethane foam into a hollow envelope using means of the type including a chamber for mixing the constituents of the polyurethane foam, a cylinder communicating with said chamber and open at both its ends, one of its ends opening into the orifice of the hollow envelope and the other end serving as inlet for a piston adapted for sliding in said cylinder and driving the polyurethane foam therefrom into said envelope, wherein said envelope is substantially vertical, its upper end opens into the orifice of the hollow envelope and is of a volume close to half that defined by the envelope and the movement of the piston in said cylinder is adjustable in synchronism with the cycle of the mixing head.

Abstract: A kit and a process for making a representative reproduction of a portion of the body of a person in a selected orientation wherein the kit includes a supply of impression material, a mold-defining cavity member, which may be in two parts, and a supply of plaster so that, the impression material, when combined with water, may be first positioned in the cavity of the mold, an impression made, after the selected body portion has been removed from the cavity, a mix of the plaster and water may be placed in the impression made in the material in the cavity allowed to set and then removed as a product representative of the body portion being reproduced.

Abstract: Uncured elastomeric sheet material (42) is built up on the outer surface of a production article (36) constructed from composite materials. A vacuum bag system (20, 24, 26, 30, 32) is used for holding the uncured elastomer member (60) against the composite article (36) while the elastomer member (60) is being cured under heat and pressure. Such curing causes the elastomer member (60) to shrink. The elastomer member (60) is then resized by cutting it into sections (66). The sections (66) are placed back on the composite article (36) and each is positioned on such article (36) at a location best conforming to it in shape. This leaves gaps (68) between the sections (66). Additional uncured elastomer (70) is applied to fill the gaps (68) and bridge across the gaps (68), to in that manner splice the sections (66) together. A vacuum bag (20, 24, 26, 30, 32) is again applied and the bag assembly (20, 24, 26, 30, 32 ) is again cured under heat and pressure, to cure the additional elastomer material (70).

Abstract: Method for preparing a shaped part, from a flexible plastic material, from a particular pattern, which comprises first forming by gun-spraying, a layer (6) plastic material over a shaping surface from a first mould (11) corresponding to an outline distorted along continuous lines, of the visible surface impression (12) of said pattern, and then stripping the layer of plastic material from the mould, laying said layer (6) inside a second mould the shaping surface of which coincides with the shape of the pattern visible surface.

Abstract: A method of roller forming thermoplastic sheet material to form large parts includes providing a form having a surface of predetermined curvature. A sheet of thermoplastic material is overlain on the form surface and heated until pliable. Pressure is provided on the thermoplastic sheet using a roller so that the sheet conforms to the shape of the form.

Abstract: A method of casting decorative emblems from a polyurethane-type compound. A series of decorvative discs are held flat and horizontal while the polyurethane composition is cast thereon to form a meniscus. The polyurethane composition comprises a polyether polyol component and a diisocyanate component. The cast polyurethane, when cured, gives a lens effect to the decorative discs.