Abstract: A thermoplastic composite sheet is used as a tool or tool liner for thermoforming thermoplastic composite sheets into parts having uneven sections. A more uniform consolidation of the part is achieved that has not been previously attainable in open mold processing at high forming temperatures.

Abstract: The invention relates to a food storing container and a method thereof, said container is formed with thermoplastic synthetic resin material and a bio-ceramic material naturally radiating extreme infrared ray is adhered to the inside surrounding surface thereof.Said bio-ceramic material is adhered to on the tape of polyester material in high density to be supplied into the surface of the inside molder as a roll type before an injection molding of a container and then the injection solution is filled thereon to mold a predetermined container, whereby the bio-ceramic material is uniformly distributed in the container, and also the container is constructed by a method of adhering the bio-ceramic material to the polyester material so that the firmness, the preservation and the ease-of-manufacturing thereof becomes high.

Abstract: An injection molding method which injects a first resin in a first cavity (1) and a second resin in a second cavity (2) with a flexible fabric and porous membrane (3) spanning the interior of the cavity to inpart define the two cavities (1, 2). The second cavity is filled with fibers (14) and is vented via vents (6). The first resin injected into cavity (1) can penetrate the membrane (3) and fuse with the second resin in cavity (2). A nozzle (5) penetrates the membrane (3) with the membrane forming a seal thereabout for delivery of the second resin to the cavity (2).

Abstract: A process for fabricating manufactured articles from fiberglass reinforced thermoplastic sheets, which consists of forming said plates while they are heated at their melting point and coupled with a barrier film, by either blow-moulding or thermoforming.

Abstract: A disposable self contained cartridge for resin transfer molding including a sealable flexible-walled vacuum bag surrounding fibrous reinforcing material to be impregnated and formed and a quantity of resin for impregnating the fibrous reinforcing material, and vacuum port to collapse the vacuum bag about the fibrous reinforcing material and the resin.

Abstract: A method and apparatus of molding articles from composite materials are disclosed in which a stack of prepregs are placed on a first forming surface of a former, which forming surface has a surface configuration matching that of one side of the composite article, placing a semi-rigid molding shelf onto the former such that a second forming surface of the molding shell, which matches the surface configuration of an opposite side of the composite article, bears against the stack of prepregs and urging the molding shell towards the former, thereby compressing the plies of prepregs by drawing a vacuum between an impermeable membrane covering the molding shell and the former. The assembly of the former, the molding shell, the stack of prepregs and the impermeable membrane are placed in an autoclave such that it may be heated while the vacuum is drawn between the membrane and the former to compress the stack of plies of prepregs.

Abstract: A patterned tool and method for producing a durable tactile warning surface for sidewalks and other walkways including pouring a concrete base, applying pigmented or colored hardener to the upper surface of the concrete base, stamping the upper surface of the concrete base with the patterned tool including a substantially flat member having a plurality of symmetrically disposed recesses of a predetermined diameter and depth formed on the lower surface thereof and a plurality of corresponding vent channels formed through the substantially flat member in communication with each corresponding recess and curing the concrete base to form a durable tactile warning surface including a plurality of symmetrically disposed raised elements of a predetermined diameter, height and spacing corresponding to the plurality of recesses to produce an uneven surface visually contrasting with adjacent surface areas.

Abstract: An unitary vacuum bag for forming of a fiber reinforced composite article, made of a curable elastomer, having molded in resin distribution means formed to the specific article to be made. Optional vacuum conduits are molded into the periphery of the bag, causing the bag to be adapted to any number of mold shapes. The vacuum bag is constructed upon that mold which forms the base for the construction of the desired fiber reinforced composite article. The bag contains an open sided, resilient main distribution conduit running laterally along the long axes of the vacuum bag with branch conduits, depending upon the shape of the mold, to provide for long distance flow of resin to all parts of the composite article. A multiplicity of cross channels are formed on the inner surface of the bag, covering most of the area under which the fiber lay up is placed within the mold.

Abstract: A process for the manufacture of tubular rubber articles includes a) forming a tube of uncured rubber on a mandrel; b) wrapping the tubular rubber by winding with a film laminate including i) at least one layer of a heat stabilized, oriented nylon film having a thickness of from 13 to 50 .mu.m and having a shrinkage of 2 to 10% in the machine direction, laminated to ii) at least one heat stabilized film selected from an oriented nylon film having a thickness of from 13 to 50 .mu.m and having a shrinkage of 2 to 10% in the machine direction, or a cast nylon film having a thickness of from 15 to 155 .mu.m and having a shrinkage of 0.5 to 1.5% in the machine direction; and c) curing the rubber at an elevated temperature.

Abstract: A switch cross tie is made in a mold having a base plate formed with a plurality of holes in a predetermined pattern corresponding to a particular type of concrete switch cross tie by first overlying the entire base plate of a mold with a covering sheet provided with markings in a pattern corresponding to that of the holes needed for another particular type of concrete cross ties. This covering sheet overlies and blocks all the holes formed in the base plate and it is fixed in place atop the base plate. Then the operator or a computer-guided drill press cuts through the covering sheet and into the base plate at each of the markings to form thereat a respective new hole. Each such new hole is fitted with an anchor, and the mold is filled with concrete over and around the anchors with the covering sheet blocking all the holes other than the new holes. It is important that the covering sheet be sufficiently strong to inhibit entry of concrete through it into any of the holes other than the new holes.

Abstract: A highly compressed covering material is fabricated by pressing a lumpy plastics material or plastics pre-product. The plastics material or plastics pre-product is thereby fed into a double-belt press by continuously and dosedly feeding the plastics material or plastics pre-product into a region formed by lateral delimiting elements at the lower belt of the double-belt press. The continuous pressing to form the highly compressed covering material is accomplished there during heating and with increasing pressure.

Abstract: Variability between composite structures can be reduced by utilizing forming and curing tooling that includes a cure tool and a preform tool. The cure tool has a curing surface. The curing surface defines the shape of a cured composite structure. The preform tool has a preform surface that is divided into at least first and second surface area portions. The first surface area portion is of the same surface shape to the corresponding surface area of the curing surface on the cure tool. The second surface portion is of a surface shape that is different from the surface shape of the corresponding surface area of the curing surface on the cure tool. The differences between the second surface area portion of the preform surface and its complementary surface on the curing surface is such that there is an increase in the surface area of the second surface area portion of the preform surface compared to a corresponding area on the curing surface of the cure tool.

Abstract: Process for vacuum impregnation of a dry fiber reinforcement with a curable resin to produce a resin-fiber composite, by drawing a vacuum to permit flow of curable liquid resin into and through a fiber reinforcement to impregnate same and curing the resin-impregnated fiber reinforcement at a sufficient temperature and pressure to effect final curing. Both vacuum and positive pressure, e.g. autoclave pressure, are applied to the dry fiber reinforcement prior to application of heat and prior to any resin flow to compact the dry fiber reinforcement, and produce a resin-fiber composite of reduced weight, thickness and resin content, and improved mechanical properties. Preferably both a vacuum and positive pressure, e.g. autoclave pressure, are also applied during final curing.

Abstract: A process for making a blow molded product which includes the steps of positioning a sheet having a surface pattern which is incompatible with a parison in a mold for blow molding; extruding a softened parison of a synthetic resin from a die head; holding the parison in the mold and blowing gas into the parison to be expanded to form a blow molded product with a surface feature of the sheet reproduced on the blow molded product; and separating the sheet and the blow molded product from each other.

Abstract: A method and apparatus for stamping a blank of plastic material, such as a soap blank, into a shaped article, such as a soap bar. The apparatus and method uses a pair of mating die halves spaced apart from one another in order to receive the blank of plastic material. Thereafter, the blank of plastic material is stamped and shaped by closing the die halves so they are mating. The die halves are then opened so as to discharge the shaped article and receive a new blank of plastic material. The present invention contemplates placing an elastomeric septum across each die half between the blank and the die half so as to prevent plastic material from sticking to the die halves after stamping. It has been found that a septum made from latex works well.

Abstract: Plastic sheets of good optical quality suitable for use in the glazings of automotive vehicles, eye glasses etc., are made by depositing a hardenable liquid mass upon a taut moving ribbon of plastic which has been pretreated by tensioning and heating to remove wrinkles and creases which otherwise would render optically unsatisfactory the sheet formed on the ribbon upon hardening of the liquid mass. The temperature range within which the pretreatment should be conducted is 60.degree.-100.degree. C., with 70.degree.-90.degree. C. being preferred; the tension applied in the pretreatment should be a dekanewton or more per square millimeter, preferably 1.5-7.5 dekanewtons per mm.sup.2 ; and the time of pretreatment is at least a minute and preferably 5 or more minutes.

Abstract: A vacuum molding process uses a flexible molding skin having an imprint face arranged inside an airtight compartment. Before the vacuum is made, a pasty plastic material is incorporated in the compartment facing the imprint The vacuum is then made in the compartment to press the flexible molding skin onto the plastic material with formation of a molded surface with sculptures and asperities giving a decorative or functional granular appearance. The molding skin is made of a flexible anti-adhesive organic material, notably silicone, for ease of removal from the mold after the plastic material has hardened Shaping of the panel is performed after the vacuum bag has been positioned on a shaping part. The process is used for manufacturing artificial climbing wall panels.

Abstract: The present invention is a contoured wall and method for creating the contour and appearance of a wall formed from individual assembled units such as stones. The wall is formed from a plurality of interlocking wall portions that each have at least two non-linear mating surfaces. Each of the wall portions further has a lateral face contoured to resemble the stone wall. The wall is formed from hardenable construction material such as concrete poured between two mold members. Each of the mold members has a lateral mold face with at least one of the lateral faces having a plurality of interlocking contoured relief portions to provide a molded surface having the contour of a stone wall. In one embodiment, at least one of the mold members includes a plurality of individual form liners, or mold modules, each of which includes two non-linear mating edges and a lateral relief mold face.

Abstract: A switch cross tie is made in a mold having a base plate formed with a plurality of holes in a predetermined pattern corresponding to a particular type of concrete switch cross tie by first overlying the entire base plate of a mold with a covering sheet provided with markings in a pattern corresponding to that of the holes needed for another particular type of concrete cross ties. This covering sheet overlies and blocks all the holes formed in the base plate and it is fixed in place atop the base plate. Then the operator or a computer-guided drill press cuts through the covering sheet and into the base plate at each of the markings to form thereat a respective new hole. Each such new hole is fitted with an anchor, and the mold is filled with concrete over and around the anchors with the covering sheet blocking all the holes other than the new holes. It is important that the covering sheet be sufficiently strong to inhibit entry of concrete through it into any of the holes other than the new holes.

Abstract: An improved method for the fabrication of lightweight ceramic matrix composite panels, utilizing pressure forming with floating tooling to shape integral stiffeners such as raised integral surface channels on panel surfaces. The consolidation of green composite material against refractory floating tools by hot hydrostatic or isostatic (gas) pressing, followed by removal of the tooling, yields a strong, rigid, yet lightweight ceramic structure.

Abstract: The present invention is a contoured wall and method for creating the contour and appearance of a wall formed from individual assembled units such as stones. The wall is formed from a plurality of mating form liners each having a reciprocal contoured surface to that of the desired stone wall. The wall is formed from hardenable construction material such as concrete poured between two mold members with the form liners attached to at least one of the mold members. Each of the form liners has a lateral relief mold face adapted to provide a molded surface having the contour of a stone wall. Each lateral relief mold face of the form liners has a latticework non-linear mortar-forming interlocking portion surrounding stone-forming recessed portions. The form liners ar positionable in a plurality of arrangements wherein the interlocking portions and recessed portions along the mating edge of each form liner mate along the mating edge of the adjacent form liner to form a continuous lateral relief mold face.

Abstract: A novel method for forming a gel matrix. In this method an apparatus is provided which includes a first and second plate, each plate having a flat surface, and a spacer. The spacer is positioned between the flat surfaces of the two plates so that the flat surfaces are located close to each other with a gap from the top of the plates to the bottom of the plates. The apparatus is placed into a generally rectangular liquid impermeable bag having one top open end, a bottom end and a side wall therebetween. The apparatus is placed into this bag such that the top of the plates is parallel to the top open edge of the bag, and the bottom of the plates is located adjacent the bottom end of the bag. The apparatus is fixed, e.g., clamped, in place firmly within the bag and a gelling solution poured into the gap between the plates. This gelling solution is then allowed to set to form the desired gel matrix.

Abstract: A process of applying catalyzed resin through a vacuum bag onto a dry hand lay-up uses at least one resin reservoir with a valve nozzle thereon. The valve nozzle is placed between the lay-up and the vacuum bag. By lifting the resin reservoir connected to the valve nozzle, the catalyzed resin placed in the reservoir will be sucked by vacuum onto the laminate. The lowering of the resin reservoir stops the flow. The vacuum bag between the valve nozzle and the reservoir connector must be broken first to allow an open channel to the valve nozzle outlet.

Abstract: A method and device for fabricating posts made of concrete having a polygonal cross-section includes the steps of providing and opening an integral liner, applying backing panels to the liner, holding the panels together with a hooping means, and pouring and hardening concrete in the integral liner. The liner is collapsible and preformed to open in the shape of a right prism with an internal section identical to that of the post to be manufactured. Backing panels made of cardboard or plastic material support the external faces of the liner and entirely cover the external faces of the liner. At least one of the backing panels is adhered to an external face of the liner. A hooping means holds the liner and the backing panels assembled in mutual contact during the use of the device.

Abstract: The method of forming a three-dimensional pattern, wherein a pattern forming mold formed from an expanded polyethylene is attached to the work surface where a desired pattern is to be formed, a surfacing material of a specific acrylic resin concrete is cast onto the work surface, the surfacing material is allowed to harden, and the mold is detached and removed from the work surface.

Abstract: A method of shaping a thermoformable composite material including a polymeric matrix reinforced with continuous filaments which involves locating the material in overlapping relationship with at least one diaphragm of a thermoformable shaping polymer, heating the assembly to a suitable thermoforming temperature and shaping the assembly against a shaping tool surface in a shaping step of less than two minutes.

Abstract: A depositing method of wall concrete, in which unset concrete is deposited in a form, includes the step of disposing a non-hygroscopic soft sheet which has a large number of hollow projections or ridges on an inner surface of the form being deformable when lateral pressure is applied thereto by the hardening of the concrete.

Abstract: A printing method for moulded plastics articles comprises printing of selected indicia onto an elastomeric film (2), locating the printed film (2) in a mould cavity (3) with the printed surface facing inwardly and the evacuating the air space between the film (2) and the mould surface (8). With the printed film (2) located firmly against the mould cavity (3), the film (2) is manipulated to bring the printed indicia into register with surface features of the mould (8). Plastics material is injected into the mould cavity (4) and during solidification, the printed indicia is transferred from the film (2) to the surface of the moulded article with the printed indicia in accurate register with surface features of the moulded article.

Abstract: A method for producing a lid device for a wide-mouthed container which comprises a lid body having an opening of a predetermined shape, and a closure member made of a soft synthetic resin for closing the opening of the lid body. According to the method, the lid body and a vapor impervious film are placed between a first mold body and a second mold body with the film located on the side of the second mold body. The first mold body has a closure forming cavity, whereas the second mold body has a tab forming cavity. A fluid synthetic resin is injected under pressure from the side of the first mold body to fill the closure forming cavity. The resin is caused to break through the film to fill the tab forming cavity, thereby forming a pull tab integral with the closure member.

Abstract: An apparatus and method for fabricating integral three-dimensional objects from successive layers of photoformable compositions by exposing the layers of the composition through a detachable flexible transparent film, one side of the film being in contact with the composition and the other side of the film with a rigid transparent plate, which guides and supports the film.

Abstract: A method and apparatus for manufacturing perforate, fiber reinforced composite material wherein the fiber reinforcing material is impregnated with the resin which is cured to give a strong light material.

Abstract: Injected fluid plastic material directed to a predetermined side of a film section that is inserted into a mold cavity by utilizing a mold that includes a first mold part with a first mold-cavity section and a second mold part with a second mold-cavity section, a gate with a gate region, and a multitude of specific flow channels in the first mold-cavity section for directing injected plastic material away from the gate region; placing the film section in the second mold-cavity section so that the film section covers an extensive region of both the specific flow channels and the thin mold-cavity region and so that the film section does not cover a first segment of each of the specific flow channels which are closest to the gate region, but does cover a second segment of each of the specific flow channels which is a continuation the first segment of each of the specific flow channels; and injecting the fluid plastic material into the mold-cavity, so that the fluid plastic material flows away form the gate regio

Abstract: A composite material for use as a molding plate in a method of shaping molding compounds in the repair and restoration of damaged surfaces. In the preferred embodiment, a layer of expanded metal is bonded to a plurality of perforated plastic strips.

Abstract: A method of densifying glass-composite structures using a superplastically deformed foil to partially encapsulate a glass-composite part and a part holding die. The die and part are contained in a rigid box held in a press. The foil is deformed over the die and part. Heat and pressure are applied to the die and part, through the rigid box, to soften the glass matrix of the part and to cause the glass to flow into the voids of the part.

Abstract: A process for preparing an injection-molded article having a three-dimensional pattern on a surface thereof includes placing a master film of a thermoplastic resin having a three-dimensional master pattern formed on a region thereof into a mold such that the master pattern is exposed to the mold cavity. An injection-moldable resin is then injected into the mold cavity so as to cause a surface region of the resin to conform to the three-dimensional master pattern on the master film, and to thereby transfer the master pattern onto said surface region of the resin. The master film is then removed from the surface region of the injection molded resin to thereby expose said three-dimensional pattern formed thereupon. Preferably the master film is formed of a thermoplastic resin having a melting point greater than the injection molding temperature. Other lower melting point thermoplastic films can be used by metallizing the film's surface so that it withstands the injection molding temperature.

Abstract: A formwork for a draft tube which includes ganged precast forms, each precast form corresponding to a curved segment of the draft tube. The precast forms are molded with continuous side plates extending thereabout and anchored in the precast concrete form and projecting beyond the surface opposite to the contact surface to provide a flange. A fastening means for attaching adjacent forms with a space therebetween to allow for stripping. A method includes determining the outline of the inner surface of the draft tube and dividing it into segments and preparing molds to make precast forms corresponding to each segment. The precast forms are assembled and shored to provide the draft tube ganged formwork, and concrete is poured about the draft tube formwork and is cured. The precast forms are stripped from the set concrete structure and reused in another draft tube formwork.

Abstract: Dental light-curing resins are cured with light and under pressure by placing the uncured resin on a cast or mold or dental appliance to be prepared then covered with a transparent or translucent flexible membrane or sheet. In a chamber gas pressure is applied to the sheet and, in turn, to all parts of the underlying resin and, while pressurized, the resin is exposed to light to cure it.

Abstract: Method and apparatus for forming thermoplastic materials provides for supporting a sheet of thermoplastic material on a support spanning a former, heating the sheet of thermoplastic material to a predetermined temperature to render the thermoplastic material plastic, thereby permitting the support and the sheet of thermoplastic material supported thereon to depend downwardly by gravity into the former, and allowing the sheet of thermoplastic material to cool in a shape at least partially defined by the former.

Abstract: A method of die forming using an elastically deformable die is characterized by using a die provided in advance with a prescribed pattern of thickness variation, allowing the die to be elastically deformed by the pressure it receives from the material being formed during the forming operation, and forming the material to the configuration resulting from the deformation.

Abstract: One method of forming a workpiece made of thermoformable material includes the steps of: (a) supporting a raw workpiece on a suspension tray; (b) moving a pair of relatively hot forming dies into position above the workpiece; (c) closing the hot forming dies against the workpiece to heat the workpiece and to form and shape the workpiece into the desired configuration; (d) opening the hot forming dies and removing the hot forming dies away from the workpiece; (e) moving a pair of relatively cold forming dies into position above and below the workpiece; (f) closing the cold forming dies against the workpiece to cool the workpiece while maintaining the workpiece in the desired configuration; and, (g) opening the cold forming dies and removing the finished workpiece form the suspension tray. Other methods are also disclosed.

Abstract: Method for press vulcanizing, not only of dry, wholly or partly vulcanizable articles (1), such as auto rubber mats, piled rubber mats, etc., of a humidity of 0-3 weight percent but also of such articles (1) of a humidity of 3-5 weight percent or more, in the press zone of a vulcanizing press (P) having a shiftable part for closing and opening of the press (P) capable of applying a uniform surface pressure against any article (1) fed into the press. In that at least from the beginning of the vulcanizing operation to the end of it, a multitude of flow routes is established between the press shiftable part and each article (1) for vapors and gases released from each article (1), and a multitude of flow routes out from the press zone from where said vapors and gases may thus escape at least along part of the border of said press zone border, a method is brought about in which no vulcanizing heat is lost for heating of confined vapors and gases at high pressures.

Abstract: Gasket used in a fabrication method, wherein a methylmethacrylate prepolymer or a mixture of unsaturated monomers, whose main constituent is methylmethacrylate, or the unsaturated monomer or monomers themselves is (are) introduced into a mold comprised of two parallel plates separated by said gasket, and the mold is brought to a temperature sufficient to complete or carry out the polymerization. The gasket consists of a core of plasticized poly(vinylchloride), said core being sheathed by a thin layer of thermoplastic polymers chosen from among propylene polymers and saturated polymers, said thermoplastic polymer being capable of retaining its elasticity at temperatures ranging from 20.degree. to 120.degree. C. and having a melting or softening point higher than 115.degree. C.

Abstract: A process for preparing non-planar thermoplastic fiber reinforced composites utilizes drapeable thermoplastic impregnated fiber reinforced prepregs in a pressure thermoforming process employing but one diaphragm. The single diaphragm when initially used is flat, but becomes deformed, following its first use, to the shape of the finished part. The diaphragm thus deformed may be repeatedly used as it will still fit over the prepreg layup.

Abstract: A process for producing an optical element wherein an optical molding is formed by using a mold and thereafter released from the mold by supplying a gas to the boundary between the mold surface and the optical molding. In the process, no localized external force is applied to the optical molding during the release thereof, and therefore undesirable deformation or flaws of the optical molding are not caused.

Abstract: Deformable insulating films are used as mold liners in a compression molding process. The film delays the initial cooling of the preheated thermoplastic charge. The film also serves as a plastic charge carrier and convection barrier during transport of the plastic charge from a heating unit into the compression molding press.

Abstract: Method for making a transportable brick panel in which a mold on which a brick panel is to be formed is set out, with the mold including a substantially flat bottom surface. A soft deformable membrane is laid over the bottom surface, with the membrane being such as to form a seal around face edges of bricks placed on it to prevent fine cementitious particles in mortar placed between the bricks from contaminating faces of the bricks. The deformable membrane is also such as to inhibit movement of bricks placed on the membrane. Courses of brickwork are arranged in the mold on the membrane, with individual bricks being substantially evenly spaced apart with spaces therebetween for receiving fluid mortar in the spaces. Reinforcing bars are arranged to pass through aligned holes in columns of bricks so as to structurally extend through the top and bottom courses of bricks. Fluid mortar is poured to fill the spaces between the individual bricks and penetrate holes in the bricks.

Abstract: Molded plastic articles are prepared by disposing a mold release membrane across a mold section, closing the mold, injecting polymeric precursor materials behind the membrane causing it to conform and adhere to the mold cavity surface, and thereafter parting the mold sections and parting the molded plastic article away from the release membrane which remains adhered to the mold cavity surface. Subsequent injections may be used to prepare additional molded plastic articles, thereby reusing the release membrane which at all times remains adhered to the mold cavity surface.

Abstract: A method for the shaping of a sheet of preform material. A flat planar (heated) sheet of preform material is held tightly between two elastomeric sheets, the sheets and preform material forming a laminate assembly. The laminate assembly is then formed about a mold having the desired contours. The elastomeric sheets maintain the preform material parallel to the surface contours of the mold as the molding process proceeds. A fluid such as air is flowed between the mold surface and the laminate assembly during the forming process to prevent the elastomeric sheets from binding on the mold surface. Wrinkles are eliminated in the final shape of the preform material, and fiber distortion of tears or rips in the material are minimized due to the fluid lubrication between the mold surface and the laminate assembly.

Abstract: A method of forming from a sintering material slurry a shaped-body to be sintered having a complicated configuration. A mold is prepared using frames, a shielding member swollen with a solvent, and a filler including a substance formed of particles, and utilizing the action of vacuum. A sintering material slurry is poured into the thus prepared mold to form a shaped-body to be sintered.

Abstract: A method of making a concrete block having decorative stones embedded in a surface thereof includes the steps of placing on a face plate a layer of stones which includes a plurality of spaced decorative surface stones and includes filler stones substantially smaller than the surface stones and disposed in the spaces between the surface stones, applying a cement mortar on the surface stones and filler stones, introducing concrete into a separate mold, inverting the face plate and placing it on top of the concrete in the mold, consolidating the concrete and assembling the concrete and the sruface stones by applying pressure and vibration, removing the mold and the face plate, and curing the resulting block without the mold.