Abstract: An improved molding apparatus is described for use with relatively light weight molds, particularly molds for articles having a plurality of voids therein. A light weight two-piece mold, one-half being substantially rigid and the other relatively flexible, is disposed in a jig. The two halves of the mold are held in sealing relationship by inserting a hollow inflatable bag between the exterior of the relatively flexible mold piece and the interior wall of the adjacent jig member and inflating said bag to a pressure superior to that exerted by the expanding foam mix in the mold.The use of the improved apparatus obviates the need for molds of high structural strength (and hence excessive weight) and gives molded articles, particularly those of complex configuration, which are free from flashing.

Abstract: Shaped, foam plastic parts are made in a lightweight shaped, open trough-like mold having a coherent sheet metal interior comovable insert and related comovable floating lid, wherein said insert is positioned and adapted to slidably elevate within the interior surface of said trough coincident with the expansion of an internally housed and expandable foamable reaction mixture. As the reaction mixture expands, the foam freely expands upwardly during a first stage of the method to at least a height of approximately 50% of that desired for the plastic part. At that point the expanding foam engages an inwardly projecting flange portion of the comovable insert upon which is seated a comovable floating lid.

Abstract: There is described a method for forming high modulus, high strength, low density solid tapered composite rods suitable for use as fishing rods and the like.

Abstract: A tapered synthetic resin pipe can be produced by winding belt-like or thread-like glass fiber around a tapered core bar, inserting it into a tapered mold and thereafter pulling out only the core bar, pouring a thermosetting synthetic resin in liquid form into the mold, inclining the mold by a predetermined angle from the horizontal position and rotating it at a predetermined rate of rotation.

Abstract: A tapered synthetic resin pipe can be produced by winding belt-like or thread-like glass fiber around a tapered core bar, inserting it into a tapered mold and thereafter pulling out only the core bar, pouring a thermosetting synthetic resin in liquid form into the mold, inclining the mold by a predetermined angle from the horizontal position and rotating it at a predetermined rate of rotation.

Abstract: An improved method for isostatically molding an elongated, cylindrical article from a powdered material. In accordance with the improved method, a mold, containing powdered material, is placed within a two-piece, perforated canister. The two pieces which form the canister are then resiliently clamped together. Thereafter, in accordance with conventional practice, the canister and the mold containing the powdered material are subjected to an isostatic pressing process. During the decompression step of this process, the mold may radially expand by pressing outwardly against the two-piece canister and thereby causing radial movement of the two-piece canister.By the use of this improved process, it has been found that long, slender rods can be isostatically molded whereas many prior art attempts to mold such rods have not been successful.

Abstract: Molding apparatus for molding articles which are free of seams and parting lines even though the articles may have severe backdraft portions. The apparatus includes a one-piece distensible flexible mold of relatively thick and self-supporting wall construction which is deformable by fluid pressure in order to release the molded article. The flexible walls of the mold include internal slits extending from the mold cavity and partially through the walls for facilitating increased expansion of the mold. The ends of the slits include transversely extending slits in order to prevent tearing of the mold wall at the end of the slit and to further facilitate expansion of the mold.

Abstract: Method of making a sculptured plastic encasement with curved transparent optical quality front and rear faces formed by separately casting each face, then encasing an object within one of the face castings. Afterward on each casting a flat open to the air surface is formed and thereafter the flat surfaces are laminated together. The unitary casting is then trimmed to size, in a way which leaves roughened edge surfaces that can hold a tint.The encasement is made from room temperature curing transparent resin, and the object encased may be a scene sculpted from fragile materials like grass, seeds, etc.

Abstract: In the manufacture of ceramic substrates by the tape casting process, improved control of thickness variations in the "green" ceramic tape is achieved by using a free-riding roller positioned within a drying chamber at a preselected location at which the cast slip has formed a dry skin yet remains fluidly deformable. The roller pressure is adjusted to a value just sufficient to redistribute the surface of the cast slip into a straight line without changing the cross-sectional area of the tape along the line of roller contact to avoid "bubble" buildup ahead of the roller and rupture of the surface skin.

Abstract: A silicone rubber mold is prepared by applying a room temperature curable, dough-like silicone composition to an area of a pattern which is vulnerable to high stress and thereafter the remainder of the pattern is coated with a flowable silicone composition which is curable at room temperature. The mold is cured and ultimately separated from the pattern being copied. The resulting silicone rubber molds may be used for high frequency flow molding.

Abstract: A method of making an insole having a heel positioner and an arch support, in which the positioning support for the heel is made in situ, in one discrete section of the foot support, and the arch support is then made, in situ, in a second discrete section.The first discrete section is made at the heel portion of the foot, in a manner so as to stabilize the plantar surface of the heel section of the foot under the cancaneous bone. This is for the purpose of eliminating, reducing or minimizing the rotation forces applied to the heel section of the foot by the weight of the body, which would normally tend to produce a pes valgus (outward bending) or a pes varus (inward bending) condition, as well as stabilizing the anterior - posterior position of the leg in its function of bearing body weight.

Abstract: Molding apparatus for molding articles without a seam or parting line even though articles may have severe backdraft portions. The apparatus includes a one-piece flexible mold which is deformable by the application of a fluid pressure differential to thereby release the finished article from the mold. The mold has a self-supporting, radially extending annular flange which forms a seal with a vacuum pot when the mold is set in the pot and the flange has a downwardly extending annular projection or lip which fits freely over the outside diameter of the side wall of the pot. The downwardly extending projection is of sufficient inside diameter to allow the flange to be easily set upon or removed from the vacuum pot and the flange also has sufficiently close tolerances with respect to the outside diameter of the pot as to accurately align and center the mold in the pot.

Abstract: Molding apparatus for molding hollow articles without a seam or parting line even though the articles may have backdraft or undercut portions on both the inside and outside surfaces. The apparatus includes a generally one-piece flexible mold having a generally thick self-supporting wall construction which is deformable by the application of a fluid pressure differential. The mold includes a generally hollow outer portion and a generally hollow inner portion integrally formed with and extending upwardly from the bottom wall of the outer portion, said mold portions defining an upwardly opening generally annular cavity into which hardenable material is placed.

Abstract: A method for using an expandable forming plug in forming apparatus such as plug assisted vacuum or pressure differential forming machines and the like wherein the plug cooperates with a mold to form hollow articles such as containers, closures, trays, and the like, from thermoplastic synthetic resinous film or sheeting. The expandable plug provides hollow articles which during forming can be programed or controlled, as desired, with respect to thickness distribution in the walls thereof and, more particularly, provides hollow articles with side and bottom walls of desired thickness, such as of substantially uniform or of a varying thickness.

Abstract: A method for molding a reinforced composite plastic structure to provide a roughened bondable surface over a portion thereof during the forming operation and which method includes molding a resin-filled, fiberglass-reinforced composite against a mold member having an elastomeric insert in the face thereof such that a portion of the fiberglass fibers are imbedded in the elastomeric member during molding so as to prevent encapsulation of the imbedded fibers by the resin and thereby leaving a roughened or three-dimensional surface over that area of the composite covered by the elastomeric mold inset.

Abstract: A font used during the plugging of bowling ball finger holes consisting of an annular member defining a chamber placed upon the bowling ball surface about the finger hole to be plugged. The font body includes a base having a concave supporting surface corresponding to the configuration of the bowling ball, and attachment means attach the font to the ball during use. The font is formed of an easily machinable material, such as synthetic plastic, and may be simultaneously machined from the ball during machining of the plugging compound and resurfacing of the ball.

Abstract: A fiber reinforced composite tube is molded by applying an annular, liquid-resin-impregnated layer of reinforcing fibers to a cylindrical mold or mandrel; placing in contact with the exposed surface of the fiber-resin layer a compression sleeve which is split lengthwise to permit circumferential contraction or expansion of the sleeve into pressurizing relation with the layer; pressurizing the compression sleeve with fluid pressure to compress the fiber-resin layer and thereby compact the reinforcing fibers and expell entrapped air and excess resin from the layer; and curing the resin while the fiber-resin layer is so compressed.

Abstract: A method is disclosed for fabricating in a single stage hollow polymeric article of manufacture from a flexible fibrous material, regardless of the degree of complexity of the laminate. The material is applied to a hollow flexible envelope which includes a pattern of any degree of complexity and which is supported on a solid mandrel, to be encased in a two-part female die. The envelope and applied material are sealed off from the mandrel by means of film layers forming a bag. A vacuum is established within the bag, resulting in forces acting from the inner side of the envelope through it and the laminated material against the die walls. The support mandrel is removed, and the remaining assembly is cured under the vacuum with or without elevated pressures. After cooling, the die and envelope are readily removed from the article.

Abstract: A method of molding elastomeric stock, the method comprising interposing an apertured, heat-resistant, flexible, insulation plate between a heated mold and the discharge portion of an elastomeric stock injection unit such that respective mold cavities provided in the mold are aligned with respective apertures in the insulation plate which intercommunicate the mold cavities with an internal discharge chamber in the injection unit. The mold and injection unit are moved relative to one another such that each presses against the other through the intermediary of the insulation plate, thereby permitting expulsion and transferring of a portion of elastomeric stock from the injection unit into the mold cavities to be cured, an excess portion of elastomeric stock remaining in the injection unit being prevented from undergoing curing by means of the presence of the insulation plate.

Abstract: A process for making a valve housing for a prosthetic socket. The process eliminates the need for a male and female mold by applying an elastic resilient separator material over the entire surface area of a housing mold, sealing one end of the material to enclose the surface area of the housing mold, applying a vacuum to the sealed material so that the material closely conforms to the entire surface area, applying an outer elastic resilient separator material to the housing mold over the reinforcing materials so as to trap the reinforcing materials to control thickness and shape, applying a vacuum thereto to force the outer elastic resilient separator and underlying reinforcement material to closely conform to the housing mold; and adding the resin molding material to impregnate the reinforcing materials.

Abstract: A method of manufacturing an open cellular article constructed of a plurality of spaced walls of relatively weak bondable material defining a plurality of elongated passages therethrough which are filled with a disintegratable filler material having sufficient form and strength initially to maintain the walls in their predetermined precisely spaced relation and after bonding of the walls into an integral unit such filler material being conveniently removable from the article to reestablish the passages between the walls.

Abstract: A flexible, distensible mold for use in fabricating art forms and utilitarian articles, and for use with the aid of air pressure differential enlargement of the shaping cavity, is provided with closeable slits extending from at least a portion of the shaping cavity partly into the mold wall, and cooperating slits extending from the outer wall of the mold into a position which is adjacent to and overlapping the internal slits. With these improved molds a withdrawal bore of the shaping cavity can be greatly enlarged and the side walls can be greatly extended with lower air pressure differentials than would be otherwise necessary. This invention provides a hinging action in the expansion of the side wall which utilizes the flexibility of the mold material to expand the withdrawal bore.

Abstract: A flexible distensible mold for use in fabricating art forms and utilitarian articles, and for use with the aid of air pressure differential enlargement of the shaping cavity is provided with closeable slits extending from at least portions of the outside surface of the mold partly into the mold. With these improved molds, the withdrawal bore of the shaping cavity can be greatly enlarged and the side walls can be greatly extended with lower air pressure differentials than would be otherwise necessary. In addition, the closed slits permits the use of thicker walls and thus provide additional support for the weight of the shaped article particularly when formed in elongated molds.

Abstract: A flexible distensible mold for use in fabricating art forms and utilitarian articles, and for use with the aid of air pressure differential enlargment of the shaping cavity, is provided with closeable slits extending from at least portions of the shaping cavity partly into the mold wall. With these improved molds the withdrawalbore of the shaping cavity can be greatly enlarged, and the side walls can be greatly extended with lower air pressure differentials than would be otherwise necessary.

Abstract: Method for compacting preheated powder bodies in a high pressure isostatic pressure vessel in which a liquid such as water is used as the pressurizing medium. A preheated workpiece is inserted into the vessel which is closed and sealed. The vessel is then rapidly filled with the liquid pressurizing medium while avoiding contact of the medium with the preheated workpiece until the vessel is substantially completely full. The pressure within the vessel is then increased rapidly to a preselected compacting level by continually pumping the liquid pressurizing medium into the vessel. The preselected compacting pressure is in excess of the critical pressure of the liquid pressurizing medium. The rapid increase of pressure within the vessel to a level exceeding the critical pressure minimizes the amount of vapor that is formed in the vessel and reduces heat transfer from the preheated body to the pressurizing system.