Abstract: A minutely working method of and apparatus for opposing the surface of a transfer member having a concave or convex pattern formed on the surface thereof and the surface of a workpiece to each other, heating the transfer member and thermally expanding the transfer member in the direction of a normal to the surface thereof to thereby transfer the concave or convex pattern to the workpiece.

Abstract: An otoplastic for a hearing aid, which otoplastic is manufactured from a UV light-curable synthetic resin composition, in particular an acrylate composition, to which a ceramic filler including at least 50% by weight Al2O3 is added to improve the properties of the otoplastic.

Abstract: A process for producing a hollow article made of a composite material of reinforcing fibers embedded in a matrix of hot-polymerized resin includes a step in which at least one core made of a silicone elastomer is draped with at least one layer of resin-impregnated reinforcing fibers. A resultant assembly is moulded to shape the internal and external surfaces of the hollow article by simultaneous inward and outward compression of at least one resin-impregnated fiber layer caused by movement of mould walls towards each other and by thermal expansion of at least one core.

Abstract: A wind tunnel blade (30) connected to a base (32) and held in position by a two-piece cuff (34). The wind tunnel blade (30) is formed in a resin transfer molding process in which central, fore, and aft foam core sections (70, 72, 74) are placed together to form the wind tunnel blade (30). Radius fillers (120) are used to fill the gaps between the outer edge of the foam core sections. The radius fillers (120) used in the wind tunnel blade (30) are formed by a braided sleeve (122) surrounding a number of unidirectional tows (124). A tip (68) is formed separately from the rest of the wind tunnel blade (30) and is glued to the top thereof. Stacked layers of braided fibers (100) are used to reinforce the central core section (70).

Abstract: A method for manufacturing a fiber rein-forced composite dental restoration comprising the steps of (i) preparing a mould; (ii) filling the cavity of the mould with a fiber-reinforced polymerizable material comprising an organic matrix and a fiber component embedded within the matrix; (iii) applying pressure to the fiber-reinforced polymerizable material; and (iv) curing the fiber-reinforced polymerizable material. The method is characterized in that the mould is designed in a way which allows excess organic matrix material to escape form the cavity during pressing.

Abstract: A method wherein a superhard abrasive material is sintered and simultaneously bonded to a sintered cemented carbide body inside a container under elevated pressure and temperature conditions (HP/HT-treatment), whereby said cemented carbide body is in contact with at least one other cemented carbide body which after the sintering is removed, is disclosed. At least the cemented carbide surfaces in contact with each other during the HP/HT-treatment is at least one coated with a 1-10 &mgr;m thick layer of a refractory oxide. The method is particularly applicable for making cemented carbide cutting inserts provided a superabrasive material and with a hole for clamping to a tool holder whereby said hole is filled with a cemented carbide plug during the HP/HT-treatment and removed thereafter. Preferably, both the plug and the insert blank are coated.

Abstract: To produce a steering wheel having a wheel skeleton with a hub, a rim and spokes interconnecting the hub and the rim, a shaped body of a dissolvable material and corresponding in shape to an airbag module is attached to the hub. The skeleton with the shaped body is placed in a mold. A plasticized molding material is molded around the rim and the spokes and over the shaped body forming a steering wheel body with a seamless casing. The steering wheel body is removed from the mold. The shaped body is then dissolved and removed, leaving a hollow space for accommodation of the airbag module.

Abstract: A wind tunnel blade (30) connected to a base (32) and held in position by a two-piece cuff (34). The wind tunnel blade (30) is formed in a resin transfer molding process in which central, fore, and aft foam core sections (70, 72, 74) are placed together to form the wind tunnel blade (30). Radius fillers (120) are used to fill the gaps between the outer edge of the foam core sections. The radius fillers (120) used in the wind tunnel blade (30) are formed by a braided sleeve (122) surrounding a number of unidirectional tows (124). A tip (68) is formed separately from the rest of the wind tunnel blade (30) and is glued to the top thereof. Stacked layers of braided fibers (100) are used to reinforce the central core section (70).

Abstract: The present invention relates to a process for producing a plastic molded article (1) having at least partly a hollow portion, and molding is conducted using a core (2) composed of a water-soluble molded article which has been formed to have the shape of the hollow portion. A plastic material is injected to cover part of the surface of the core (2), and subsequently injected to cover the remainder of the surface of the core (2), followed by finally removing the core (2) with water.

Abstract: A method for forming removable dentures using injection molding techniques wherein a cyanoacrylate base material is applied to the sides of the denture teeth, an activator or accelerator compound being sprayed onto the deposited base material whereby the base material is rapidly cured. The denture is then placed in the lower half of a mold, or flask, and a plurality of sprues are positioned therein. The upper flask portion is then attached to the lower half and the assembled flask is then invested with plaster material. The activated gel enables the teeth to be retained in position in the lower half of the flask. The flask is then placed in hot or boiling water and then deflasked to remove the melted wax. The flask is then reassembled and polymer injected therein filling the areas previously occupied by the wax. After the polymer is cured, the prothesis is removed, polished and then returned to the dentist.

Abstract: A method for molding and aligning microstructures on a patterned substrate using a microstructured mold. A slurry containing a mixture of a ceramic powder and a curable fugitive binder is placed between the microstructure of a stretchable mold and a patterned substrate. The mold can be stretched to align the microstructure of the mold with a predetermined portion of the patterned substrate. The slurry is hardened between the mold and the substrate. The mold is then removed to leave microstructures adhered to the substrate and aligned with the pattern of the substrate. The microstructures can be thermally heated to remove the binder and optimally fired to sinter the ceramic powder.

Abstract: A tooling concept uses a compliant forming surface for forming composite parts. The tooling concept utilizes a rigid support substructure that has a thin compliant forming surface. In the preferred embodiment of the invention, the tooling concept is used to form a composite sine wave spar. A preferred embodiment of the tooling concept includes upper and lower tool inserts and side tool inserts. The upper tool insert has a compliant forming surface that is located in between a rigid support substructure and the composite material used to form the composite part. Composite prepreg is laid up over a sine wave contour on the upper and lower tool inserts to form upper and lower U-shaped composite workpieces. The upper and lower tool inserts and workpieces are then brought together to form a sine wave I-beam. Radius fillers are then applied to the intersections between the upper and lower composite workpieces and cap strips are placed over the flanges of the joined composite workpieces.

Abstract: A method for making grid-stiffened structures as provided. The method includes providing a base tool having a plurality of grooves and an expansion tool having a plurality of compaction grooves therein for fitting into a plurality of the base tool grooves so as to define compaction grooves therein. A plurality of prepreg tows are then wound into the compaction grooves. A skin is then placed over the so-wound tows, the expansion tool and the base tool to define an assembly. The assembly is then bagged and autoclaved so that the expansion tool expands to provide lateral pressure to compact the prepreg tows in the compaction grooves to shape same into ribs to form a rib-stiffened structure. An analytical thermal model is developed to predict the behavior of the expansion tool.

Abstract: A method for fabricating composite structures is provided that includes providing a skin (20) that has at least one layer (160) of uncured composite material, and providing a flexible hinge tool (100) that has first and second tooling portions (110, 120) coupled with a flexible hinge (140). The first and second tooling portions (110, 120) of the hinge tool (100) each have a molding surface (112, 122), and the tooling portions (110, 120) are configured to form at least a portion of a stiffening member (10). The method further includes laying up at least one layer (160) of uncured composite material on the molding surfaces (112, 122) to form the stiffening member (10).

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: The invention relates to a method for manufacturing a fiber reinforced composite comprising the steps of (i) preparing a mould; (ii) filling the cavity of the mould with a fiber-reinforced polymerizable material comprising an organic matrix and a fiber component embedded within the matrix; (iii) applying pressure to the fiber-reinforced polymerizable material; and (iv) curing the fiber-reinforced polymerizable material. The method is characterized in that the mould is designed in a way which allows excess organic matrix material to escape form the cavity during pressing.

Abstract: A toroidal core is produced on a rim 1 comprising a central portion connecting two annular lateral anchoring zones. The rim has an air passage orifice which can be selectively closed or opened and connected to a source of pressure, to the atmosphere or to vacuum. A conduit 3 passes through the rim and has a valve 30 which can be selectively closed or opened, the conduit extending to an orifice to which a pipeline can be connected by a suitable flange 13. A stretchable membrane 2 is mounted on the radially outer side of the rim and is fastened to it in air-tight manner on anchoring zones over the entire periphery of said rim so as to define a closed space on the radially outer side of said rim between the rim and the membrane. A fluid 6 fills said closed space to overflowing, said membrane being pressed against a mold 5.

Abstract: A method of making a fender protective structure having a layer of resilient plastic/elastomer alloy having a delayed elastic response, comprising providing a mold, placing elastomer spacers in the mold, adding the plastic and elastomer to the mold under heat and pressure, and opening the mold and removing the spacers to create voids the alloy.

Abstract: The present invention provides a profiling process which allows for the material sheet to be profiled so that the surface is minimally affected and only slight plastic deformation of the material occurs, and yet uniform three-dimensional structuring takes place. Additionally, the present invention allows for an improved inherent stability in the plane of the profiled material sheet to be achieved while only minimally affecting the cross-section.

Abstract: Spinnable balls each having two surfaces with different optical characteristics can be produced by forming a plurality of balls with the same specific gravity on a thermoplastic film, and softening the thermoplastic film by controlling a heating temperature thereof based on the specific gravity of the balls so that the hemispheres of the balls are embedded into the thermoplastic film by their own weight. A layer having different optical characteristics from those of the balls is then formed on the exposed surface of each ball. Finally, the balls provided with the layers are detached from the thermoplastic film.

Abstract: A fossil molding fabrication method includes the steps of (1) preparing a fossil skeleton material; (2) mixing the fossil skeleton material with water to form a paste-like fossil skeleton material, then filling the paste-like fossil skeleton material in the cavity of a flexible mold; (3) preparing a base rock material, then mixing the base rock material with water to form a paste-like base rock material, and then covering the paste-like base rock material over the fossil skeleton in the flexible mold; and (4) keeping the paste-like base rock material away from the radiation of the sun and letting it be dried in the air, and then removing the molding thus formed from the mold, so as to obtain a fossil molding. A cover rock may be covered on the base rock over the fossil skeleton.

Abstract: According to the invention thin sheets of foil are stiffened in a particular way by means of vault-structuring. The vault-structuring occurs either by self-organizing or following a self-organized design with a spade-shaped or drop-shaped pattern.

Abstract: A method and apparatus for covering a roll core with a polymeric material, preferably a high performance thermoplastic material, is disclosed. The method includes first providing a cylindrical roll core having two ends, a length, and an outer surface. A spacer assembly is attached proximate one end of the roll core, the spacer assembly having a circumference greater than that of the roll core. After preheating to a desired temperature, the roll core is then placed within an apparatus in a substantially vertical orientation and held therein by suitable fixtures, e.g., opposed universal chucks. A length of mold tape is helically wound over the length of the roll core in a spaced-apart relationship therewith to define an application zone between the mold tape and the roll core outer surface. A filament formed of the polymeric material is extruded within the application zone and helically wound over the roll core outer surface so that the roll core is covered with the material.

Abstract: A generally tubular device (e.g., a stent or catheter) for placement in a lumen of a patient's body is made by forming a depressed pattern in an external surface of a mold. The depressed pattern corresponds to a desired shape of the generally tubular device. A material is deposited in the depressed pattern for the material to form the generally tubular device conforming to the depressed pattern. The generally tubular device is separated from the mold.

Abstract: A method and apparatus for moulding ice statues using a mould formed of a liquid impervious flexible material which defines a mould cavity having the shape of the statue to be formed and a pair of extending wall portions which are held in a juxtaposed attitude during the freezing process. For demoulding, the wall portions are moved apart to increase the cross-sectional size of the mould to allow it to be released from the statue formed.

Abstract: Improved methods for manufacturing a shaft for a golf club, devices useful in such methods, and golf club shafts manufactured in accordance with such methods. A plug is detachably affixed to a distal end of a mandrel. A plurality of plies pre-preg composite sheet are wrapped around the mandrel and plug and, thereafter, heated causing the resin comprising the various plies to be cured. The mandrel is then removed from the formed shaft, leaving the plug as an integral part of the distal tip of the shaft.

Abstract: A method and apparatus for the manufacture of fiber reinforced structures. The tooling and its use for the manufacture of reinforced structures is described and illustrated.

Abstract: A method for forming a vehicle headliner comprises providing at least one layer of formable material and a cover member; heating the layer and the cover member; providing a mold having a pair of mold halves and a compressible seal disposed between the mold halves, at least one of the mold halves having an aperture and a channel in communication with the aperture; positioning the layer and the cover member between the mold halves; bringing the mold halves toward each other to effect a sealed relationship; and applying a vacuum pressure to the aperture to sufficiently draw the mold halves together and compress the seal, thereby compressing the at least one layer and the cover member together to form the headliner.

Abstract: A dynamic mold seal for a mold having two relatively movable mold halves is provided. The dynamic mold seal is formed by a sealing ring mounted or secured to a first one of the mold halves. The sealing ring includes a rigid ring portion and a sealing portion including a flexible sealing member for preventing leakage of the pressurized molten material from the mold and thereby preventing the creation of flash about the molded article. The flexible sealing member is preferably formed by a reduced cross section portion of the sealing portion.

Abstract: A method of forming a flexible mold (12) and resulting article is provided where a model (10) having the contour of the article to be molded is provided. The model (10) is partially encapsulated within a flexible and substantially liquid impervious layer (14). The combined model (10) and liquid impervious layer (14) is immersed into a curable liquid composition and handle members (36, 38) are inserted into the curable liquid composition. The curable liquid composition (34) is cured having the handles (36, 38) embedded within the composition (34) and subsequent to curing, forms a solid flexible mold encompassing structure (44). Handle members (36, 38) are actuated to release the model (10) from the layer (14) to form the flexible mold (12) for the article to be produced.

Abstract: A molded fabric treatment includes an integral undercut or inturned peripheral flange for affixing the treatment to the structure to be treated. The treatments have a conventional, decorative, woven polyester fabric (of the type currently used in conventional office divider screen systems), or fabrics comprising other synthetic or natural fibers, bonded with adhesive to a relatively stiff moldable non-woven polyester fiber backing. The treatments are formed in a membrane or bladder press in which a flexible membrane presses the fabric and fiber composite against a form or mold that includes an undercut edge which, in cooperation with the press membrane, forms undercut flanges about the periphery of the treatment. The undercut or inturned flange may then be "snapped" over a corresponding mounting lip on the structure to be treated.

Abstract: There is provided a method of deforming the hook head portions of hook elements on a web backing. The hook elements on the web backing are fed into a nip formed between a support surface and an upper heated surface having a durameter hardness of less than 90 Shore A. This upper heated surface compressively engages the hook head causing it to turn down and permanently deform. This increases the uniformity of the hook head elements forming a fiber engaging crook region.

Abstract: According to the present invention there is provided a method of making a cutting insert with a hole for clamping to a tool holder wherein a super-hard abrasive material is sintered and simultaneously bonded to a sintered cemented carbide body with a hole inside a container under elevated pressure and temperature conditions. During sintering the hole is filled with a plug which after sintering is removed.

Abstract: A manufacturing method for U-bolts comprising the steps of (a) winding a linear, tape or cloth member made of fiber reinforced plastics in which at least a part of the fiber is oriented in three-dimensional directions around a mandrel having a substantially oval or rectangular section (b) making a pipe molded article by hardening the linear, tape or cloth member wound around the mandrel, (c) cutting the hardened pipe molded article into slices transverse to a longitudinal axis of the mandrel, (d) separating the molded article cut into slices into at least two U-shaped portions, and (e) forming screw portions at tip portions of a pair of separated U-shaped portions.

Abstract: For the production of a steering wheel with a seamless casing, surrounding the steering wheel rim, the steering wheel spokes and the central region for an airbag covering with tear-open lines, of a plastic moulded part produced in one piece by casting or injection moulding, with a closed surface and a possibly foamed base body, a method is proposed which is characterized in that a core of a low-melting material is fastened to the central base part of the steering wheel skeleton structure, that thereafter the steering wheel skeleton structure and the core are placed into a mould for the formation of the plastic moulded part, that the plastic moulded part is produced and that after the setting of the plastic moulded part, the core is melted by an increase in temperature and the material is removed in liquid form from the plastic moulded part.

Abstract: A molding apparatus for forming a molded piece that includes a positive impression of an object, the molded piece comprising a monolithic block that is larger than the object. The apparatus comprises a container in which a negative impression of the object is formed by casting it in a fast-setting flowable compound, and a mold extension that snaps on to the container and provides an additional mold volume that is contiguous with the negative impression. The invention further comprises a mixing apparatus for mixing fast-setting compounds. In one embodiment, the mixing apparatus comprises a cylindrical jar with a screw-on lid. A rod passes through an aperture in the lid and moves axially with respect to the jar. The end of the rod external to the jar is configured as a handle, and the end of the rod internal to the jar is connected to a circular mesh. The circular mesh is oriented parallel to the bottom of the jar and has an outer diameter which is slightly less than the smallest inner diameter of the jar.

Abstract: The invention proposes a process for bladder moulding thin articles made of a composite material consisting of fibre and polymerised resin, the articles comprising corners having a rounded vertex and produced by a shaper. Such a process is distinguished in that the surface experiencing the air pressure is convex and the normals to the surface converge on the rounded shaping vertex of the shaper.

Abstract: Rapid prototyping methods and apparatuses that produce structures made of continuous-fiber polymer-matrix composites without the use of molds. Instead of using molds, the composite structure is fabricated patch by patch in layers or wraps, using a two- or three-axis stage connected to a rapidly-reconfigurable forming surface, and a robot arm to position the evolving composite structure, which are both programmable devices. Because programmable devices are included, i.e., a robot and a two- or three-axis stage connected to the reconfigurable forming surface, the control program needed to produce a desired shape can be easily modified to automatically generate the desired shape from an electronic model (e.g., using a CAD/CAM system) of the desired (predetermined) shape.

Abstract: A motor vehicle dashboard including a body made of injection-molded plastic form, and at least one air duct integrally molded with the dashboard body. The air duct is produced by means of an at least partially absorbable removable insert, particularly an inflatable balloon.

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: A tool for molding the surface of a resin sealant deposited within a generally U-shaped groove formed by two overlapping pieces that includes an elongated member shaped and dimensioned to fit within the groove and contact the surface of the sealant.

Abstract: In a method for the arc-like shaping of an extruded profiled strand of plastic material at least a section of the strand is heated in a hot air chamber together with a support ledge disposed in spaced relationship from the profiled strand to a temperature permitting the bending of the profiled strand and the strand is then firmly engaged between a support ledge at the inner compression side and a support profile at the other, that is the tension side of the profile strand to form a package, which is then bent. Preferably, the temperature at the compression side of the profile strand is higher than the temperature at the tension side thereof to prevent the formation of waves in the profile strand walls. The profile strand may be surrounded by support profile members, which are heated together with the profile strand. The support profile members are held in engagement with profile strand by auxiliary support profiles, which are held together and which are flexible to permit bending of the whole package.

Abstract: A method for producing high performance components by the consolidation of powdered materials under conditions of hot isostatic pressure. The method uses the inclusion of reactive materials mixed into pressure-transmitting mold materials and into the powder to be consolidated to contribute to in-situ materials modification including purification, chemical transformation, and reinforcement. The method also uses encapsulation of the mold in a sealed container to retain the mold material in position, and to exclude air and contaminants.

Abstract: A tooling concept uses a compliant forming surface for forming composite parts. The tooling concept utilizes a rigid support substructure that has a thin compliant forming surface. In the preferred embodiment of the invention, the tooling concept is used to form a composite sine wave spar. A preferred embodiment of the tooling concept includes upper and lower tool inserts and side tool inserts. The upper tool insert has a compliant forming surface that is located in between a rigid support substructure and the composite material used to form the composite part. Composite prepreg is laid up over a sine wave contour on the upper and lower tool inserts to form upper and lower U-shaped composite workpieces. The upper and lower tool inserts and workpieces are then brought together to form a sine wave I-beam. Radius fillers are then applied to the intersections between the upper and lower composite workpieces and cap strips are placed over the flanges of the joined composite workpieces.

Abstract: A lipstick making device includes a mold piece having one or more mold cavities for receiving the lipstick materials and having a pattern extended inward of the mold cavity for forming a corresponding pattern in the lipstick material after the lipstick material is cured. One or more actuators are attached to the mold piece for expanding the mold piece and for disengaging the pattern of the mold piece from the lipstick material and for allowing the lipstick material to be easily removed from the mold piece without damaging the pattern formed in the lipstick material.

Abstract: The method of forming a light-weight, fiber-reinforced, particularly glass fiber-reinforced-thermoplastic resin product includes the steps of melting and mixing thermoplastic resin pellets containing parallely oriented fibers 2-100 mm long, injecting the melted resin into a cavity which is closed so that its volume is smaller than that of the final molded product, and, before or after the resin injection is completed, opening the cavity until its volume is equal to that of the final molded product. Unlike the conventional injection-molded products, this product does not require a foaming agent and, if it uses any, requires only a small amount of foaming agent. The product thus formed is light in weight and has fibers uniformly entangled inside, providing an excellent appearance of the surface. Further a skin layer is formed over the surface. These features combined with the reinforcement by the glass fibers offer high strength and high stiffness.

Abstract: A method of an integrated molding by integrally pressurizing and compressing by use of means of an upper mold and a lower mold, by use of a silicone rubber. A silicone rubber has excellent resiliency, thermal resistance, separating ability from the molds and the like. By use of a silicone rubber, a working efficiency for carrying out the integrated molding can be improved and a compressing timing can be easily taken. A method according to the invention comprises steps of: uniformly coating a mixture of a foamed urethane body on a silicone rubber horizontally held; and integrally pressurizing and compressing for a certain period by an upper mold and a lower mold. The step of uniformly coating the mixture is carried out by using a spraying technique. The silicone rubber can be attached on an inner surface of the lower mold by use of means of vacuum suction.

Abstract: A sculptor's pressure vessel having a frame, a pressure container and an expandable member for pushing the pressure container against a portion of the frame to seal the container. A pressurized gas supply is connected expandable member to inflate it and to push the pressure container against the top of the frame to seal the pressure container. The pressurized gas supply is also connected to the frame top to pressurize the pressure container when it is in sealed contact with the frame.

Abstract: The present invention is a process for making a nanochannel glass (NCG) rica, having the steps of: coating a face of an etched NCG with a replica material (with or without an intervening buffer layer), where the etched NCG face has a plurality of channels arranged in a desired pattern, to form a replica coating on the NCG conforming to the pattern; and removing the replica coating from the etched NCG. The present invention is also the replica made by this process.

Abstract: An extruded-in fabric hinge comprised of a fabric hinge member extruded-in with a first member and a second member such that at least some of the fibers of the fabric hinge member are embedded within the first and second members. An extruder apparatus with an extrusion cavity comprised of a first surface with a first adjustable mandrel, a second surface, a third surface, and a fourth surface integrated to form the extrusion cavity is used to make the extruded-in fabric hinge. A fabric hinge member is captured between the first adjustable mandrel and the second surface, and an extrusion material is extruded through an extrusion inlet of the extruder apparatus and into the extrusion cavity. The extrusion material integrates with the fabric hinge member such that at least some of the fibers of the fabric hinge member are embedded into the first and second members of the extruded-in fabric hinge.